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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Modelling of cracking during beam oscillation laser welding of a creep-resistant nickel alloy

During high power laser welding of Inconel 740H, horizontal solidification cracks form at locations between approximately 70–80% of the weld depth. With the integration of circular beam oscillation, the laser energy density distribution and underlying thermo-mechanical conditions were altered. By coupling three-dimensional heat transfer, fluid flow, and stress modelling tools, the role that circular beam oscillation plays in the formation of the strain rates and stresses driving this cracking phenomenon was identified. While the addition of a circular oscillation pattern appeared to lower the stress levels along the solidification front, it did not eliminate the appearance of horizontal cracking. Only when the beam amplitudes reached 1.6 mm did solidification cracking disappear, but the weld depths were also significantly reduced.

Gao, Mingze↗
DOE OSTI2026

X-ray observation of individual Ti-6Al-4V spherical powder particle impact in an in-situ operando laser directed energy deposition system

Understanding the particle capture mechanism in the laser directed energy deposition additive manufacturing process provides a foundation for improving productivity and reducing material loss. Capturing this phenomenon is challenging due to its highly transient time interval. To analyze the impact behavior of spherical Ti-6Al-4V powder, a custom laser directed energy deposition system was designed to control the deposition of individual particles. Synchrotron X-ray imaging at 24 kHz monitored the impact dynamics of individual powder particles. A multi-physics model based on the Smoothed-Particle Hydrodynamics scheme supported the analysis by providing the temperature and velocity fields of the molten pool. Results revealed that in laser directed energy deposition, surface tension forces dominated the powder–molten pool interaction. Hydrophobic Ti-6Al-4V powder particles had an equilibrium contact angle of 121 degrees with their molten state. Furthermore, Ti-6Al-4V powder particles required a high impact velocity (6 to 12 m/s) to transition from oscillation to submergence behavior. Lastly, oscillating powder particles that impacted near the location of the laser beam exhibited faster melting, highlighting the contribution of the laser beam to the melting mechanism. This work lays the foundation for investigations of powder particle impact in laser directed deposition and supports the validation of numerical models of powder–molten pool interactions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Ionization-Based Optical Structures for the Control of Short-Pulse Lasers (Abbreviated LDRD Report)

The intensity of light from the highest-power lasers is limited by the size of the optics required to amplify, compress, transport, and focus a laser beam. Indeed, optics damage puts strict constraints on the laser energy density that solid optics can sustain; this leads to enormous optics sizes and limits the maximum intensity that these lasers can achieve. In this project we investigated new types of diffractive optics based on mixtures of neutral gas and plasmas. The basic idea is to interfere laser beams in a gas near the ionization threshold, so that plasma is created in the constructive interference regions (i.e., the “bright” fringes of the interference pattern) while the destructive interference regions remain a neutral gas. The resulting refractive index modulation, due to the different indices in gas vs. plasma, effectively turns such structures into diffractive optics elements. We proposed several new types of optics based on this general concept: i) reflection gratings, which can act as mirrors of “pulse cleaners” to eliminate laser pre-pulse; ii) transmission gratings, as part of a new type of pulse compression scheme with the potential to achieve laser intensities orders of magnitude above what is currently feasible using solid-state optics; and iii) holographic lenses, to focus high-power lasers. We conducted laboratory experiments which demonstrated high efficiency reflection gratings, paving the way for practical applications of our new concepts.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

“Beam à la carte”: Laser heater shaping for attosecond pulses in a multiplexed x-ray free-electron laser

Electron beam shaping allows the control of the temporal properties of x-ray free-electron laser pulses from femtosecond to attosecond timescales. Here, we demonstrate the use of a laser heater to shape electron bunches and enable the generation of attosecond x-ray pulses. We demonstrate that this method can be applied in a selective way, shaping a targeted subset of bunches while leaving the remaining bunches unchanged. This experiment enables the delivery of shaped x-ray pulses to multiple undulator beamlines, with pulse properties tailored to specialized scientific applications.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Method of making a distributed optical fiber sensor having enhanced Rayleigh scattering and enhanced temperature stability, and monitoring systems employing same

A method of making an optical fiber sensor device for distributed sensing includes generating a laser beam comprising a plurality of ultrafast pulses, and focusing the laser beam into a core of an optical fiber to form a nanograting structure within the core, wherein the nanograting structure includes a plurality of spaced nanograting elements each extending substantially parallel to a longitudinal axis of optical fiber. Also, an optical fiber sensor device for distributed sensing includes an optical fiber having a longitudinal axis, a core, and a nanograting structure within the core, wherein the nanograting structure includes a plurality of spaced nanograting elements each extending substantially parallel to the longitudinal axis of the optical fiber. Also, a distributed sensing method and system and an energy production system that employs such an optical fiber sensor device.

42 ENGINEERING↗
DOE OSTI2022

Method of making a distributed optical fiber sensor having enhanced Rayleigh scattering and enhanced temperature stability, and monitoring systems employing same

A method of making an optical fiber sensor device for distributed sensing includes generating a laser beam comprising a plurality of ultrafast pulses, and focusing the laser beam into a core of an optical fiber to form a nanograting structure within the core, wherein the nanograting structure includes a plurality of spaced nanograting elements each extending substantially parallel to a longitudinal axis of optical fiber. Also, an optical fiber sensor device for distributed sensing includes an optical fiber having a longitudinal axis, a core, and a nanograting structure within the core, wherein the nanograting structure includes a plurality of spaced nanograting elements each extending substantially parallel to the longitudinal axis of the optical fiber. Also, a distributed sensing method and system and an energy production system that employs such an optical fiber sensor device.

Chen, Peng Kevin↗
DOE OSTI2021

Resistive AC-Coupled Silicon Detectors: principles of operation and first results from a combined analysis of beam test and laser data

This paper presents the principles of operation of Resistive AC-Coupled Silicon Detectors (RSDs) and measurements of the temporal and spatial resolutions using a combined analysis of laser and beam test data. RSDs are a new type of n-in-p silicon sensor based on the Low-Gain Avalanche Diode (LGAD) technology, where the n+ implant has been designed to be resistive, and the read-out is obtained via AC-coupling. The truly innovative feature of RSD is that the signal generated by an impinging particle is shared isotropically among multiple read-out pads without the need for floating electrodes or an external magnetic field. Careful tuning of the coupling oxide thickness and the n+ doping profile is at the basis of the successful functioning of this device. Several RSD matrices with different pad width-pitch geometries have been extensively tested with a laser setup in the Laboratory for Innovative Silicon Sensors in Torino, while a smaller set of devices have been tested at the Fermilab Test Beam Facility with a 120 GeV/c proton beam. The measured spatial resolution ranges between 2.5μm for 70–100 pad-pitch geometry and 17μm with 200–500 matrices, a factor of 10 better than what is achievable in binary read-out (bin size/12). Beam test data show a temporal resolution of ~40ps for 200 μm pitch devices, in line with the best performances of LGAD sensors at the same gain.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Stability of zirconium hydride

This reports complete Milestone M2.2.1 Stability of zirconium hydride: Experimental investigation of the hydrogen concentration of encapsulated zirconium hydride before and after joining. In this milestone, we first report the successful fabrication of crack-free bulk zirconium hydride by using the ORNL static hydriding system. The fabricated hydride was characterized by using X-ray diffraction (XRD) and X-ray computed tomography (XCT). XRD results showed that the δ-phase zirconium hydride, α-zirconium, and ε-phase hydride were present. XCT confirmed the absence of the internal cracking. The hydrogen concentration was determined by the weight change before and after hydrogen loading, given the fact that the oxide phase was not found during XRD analysis. Two metallic cladding materials, i.e., molybdenum and FeCrAl, were selected to encapsulate the fabricated zirconium hydride pellets. Demonstration capsules were designed and machined. Mo crucible was successfully sealed by using a combination of electron beam welding and gas tungsten arc welding. Due to the undesired neutronics property of Mo, further investigation of this cladding material was not pursued. Electron beam welding and laser beam welding were employed to seal the FeCrAl capsules. XRD were performed on the zirconium hydride before and after the sealing. The results showed that the welding process has negligible impact on the hydrogen content in the FeCrAl-canned zirconium hydride. The presented work fulfilled the proposed work under this milestone and paves a pathway to fabricate single-phase zirconium hydride and to develop robust cladding materials to can bulk zirconium hydride.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Toward high laser power beam manipulation with nanophotonic materials: evaluating thin film damage performance

Nanophotonic materials enable unprecedented control of light-matter interactions, including the ability to dynamically steer or shape wavefronts. Consequently, nanophotonic systems such as metasurfaces have been touted as promising candidates for free-space optical communications, directed energy and additive manufacturing, which currently rely on slow mechanical scanners or electro-optical components for beam steering and shaping. However, such applications necessitate the ability to support high laser irradiances (> kW/cm 2 ) and systematic studies on the high-power laser damage performance of nanophotonic materials and designs are sparse. Here, we experimentally investigate the pulsed laser-induced damage performance (at λ ∼ 1 µm) of model nanophotonic thin films including gold, indium tin oxide, and refractory materials such as titanium nitride and titanium oxynitride. We also model the spatio-thermal dissipation dynamics upon single-pulse illumination by anchoring experimental laser damage thresholds. Our findings show that gold exhibits the best laser damage resistance, but we argue that alternative materials such as transparent conducting oxides could be optimized to balance the tradeoff between damage resistance and optical tunability, which is critical for the design of thermally robust nanophotonic systems. We also discuss damage mitigation and ruggedization strategies for future device-scale studies and applications requiring high power beam manipulation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Wavefront preserving X-ray optics for Synchrotron and Free Electron Laser photon beam transport systems

We report in the last two decades, after the first light from the new Free Electron Lasers, either in the UV (FLASH and FERMI@Elettra) or X-ray (LCLS and SACLA), more and more new diffraction limited sources have been either constructed or planned. Third generation storage rings are upgraded to provide a more collimated, brighter, and coherent light for the next generation experimental techniques. X-ray optics are the bridge between the light sources and the experimental stations. They are the key to the success of advanced experiments but also the potential bottleneck preventing the exploitation of the full characteristics of the source. The beam degradation originated by any mirror defect (either from mirror polishing or from contamination) is amplified with a coherent source. Delivering diffraction-limited spots, including the option for variable spot sizes in and out of focus, requires the control of the surface of the optics at the 1 nm rms level, if not better. At LCLS, only very recently an almost perfectly uniform beam out of focus has been obtained in the hard X-rays. It has been obtained after two 1-m long mirrors with 0.5 nm rms shape precision (after installation). Those mirrors were not readily available just a decade ago. But, thanks to the pioneering work performed at the Osaka University, those optics are now commercially available with arbitrary tangential profiles. This new generation of mirrors permits achieving unprecedented results. However, they do not remove all road blocks to a perfect photon transport system. Instead, they highlighted the critical importance of mirror mounting, handling of the thermal deformation, and the need of advanced diagnostics to properly exploit all the new potentiality of these optics. Besides the need of “perfect” mirrors, other aspects of the beamline design and elements may impact the quality of the beam in the experimental station, from the lack of blaze gratings to the need of advanced simulation tools, just to cite two. In this article, after a brief historical excursus, we will present the current state of the art of mirrors, gratings, crystals, lenses, diagnostics, and simulation tools. The main problems yet to solve and a look ahead at what would be achievable in the next decade will give the reader an idea on the search for an almost ideal photon transport system and how the path toward experiments, not conceivable today, will unfold.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

System and method for high power diode based additive manufacturing

The present disclosure relates to a system for performing an Additive Manufacturing (AM) fabrication process on a powdered material, deposited as a powder bed and forming a substrate. The system makes use of a laser for generating a laser beam, and an optical subsystem. The optical subsystem is configured to receive the laser beam and to generate an optical signal comprised of electromagnetic radiation sufficient to melt or sinter the powdered material. The optical subsystem uses a digitally controlled mask configured to pattern the optical signal as needed to melt select portions of a layer of the powdered material to form a layer of a 3D part. A power supply and at least one processor are also included for generating a plurality of different power density levels selectable based on a specific material composition, absorptivity and diameter of the powder particles, and a known thickness of the powder bed. The powdered material is used to form the 3D part in a sequential layer-by-layer process.

El-Dasher, Bassem S.↗
DOE OSTI2026

Design of a non-invasive laser-based beam profile monitor system for the new Fermilab PIP-II superconducting H- linac

As part of the new Proton Improvement Plan (PIP-II), Fermilab is undertaking the development of a new 800 MeV, 2 mA H- superconducting RF linac to replace its present normal conducting 400 MeV linac. The PIP-II linac consists of a series of superconducting RF cryomodules from 2.1 MeV to 800 MeV. To limit the potential damage to the superconducting RF cavities, PIP-II will utilize non-invasive laser-based monitors (laserwires) to obtain beam profiles via photoionization. This paper will present the design of this PIP-II laserwire system including the picosecond pulsed laser, optical transport line, 13 individual laserwire stations, laser feedback and timing controls. The paper also describes the signal detection system and operation of the profile measurements.

Scarpine, Victor [Fermilab]↗
DOE OSTI2025

Design of a Non-Invasive Laser-based Beam Profile Monitor System for the New Fermilab PIP-II Superconducting H- Linac

As part of the new Proton Improvement Plan (PIP-II), Fermilab is undertaking the development of a new 800 MeV, 2 mA H- superconducting RF linac to replace its present normal conducting 400 MeV linac. The PIP-II linac consists of a series of superconducting RF cryomodules from 2.1 MeV to 800 MeV. To limit the potential damage to the superconducting RF cavities, PIP-II will utilize non-invasive laser-based monitors (laserwires) to obtain beam profiles via photoionization. This paper will present the design of this PIP-II laserwire system including the picosecond pulsed laser, optical transport line, 13 individual laserwire stations, laser feedback and timing controls.

Scarpine, V. [Fermilab]↗
DOE OSTI2021

System and method for curved light sheet projection during two-photon polymerization

A laser-based manufacturing system is disclosed for fabricating non-planar three-dimensional layers. The system may have a laser for producing a laser beam with a plurality of optical wavelengths. An optically dispersive element may be used for receiving the laser beam and splitting the beam into a plurality of distinct beam components, wherein each beam component has spatially separated optical spectral components. A phase mask may be used which is configured to receive at least one of the beam components emerging from the dispersive element and to create a modified beam. One or more focusing elements may then be used to receive the modified beam emerging from the phase mask and to focus the modified beam into a non-planar light sheet for use in fabricating a part.

Saha, Sourabh Kumar↗
DOE OSTI2023

Laser and optical transport line for laser-based ion beam diagnostics and control in the SNS linear accelerator

We report our recent upgrade of the laser and optical transport line for the laser-based ion beam diagnostics (laser wire) system at the linear accelerator (linac) of the Spallation Neutron Source (SNS). A new light source based on diodepumped solid-state laser amplifiers has been developed to provide near diffraction-limited laser beam with a variety of pulse structures. The free-space optical transport line has been modified to include image relay optics with remote control, which greatly improved the laser beam quality and position stability at individual measurement stations. The upgraded system enables novel beam diagnostics/control capabilities including longitudinal profile measurement and high-energy proton beam extraction from the SNS linac.

Liu, Yun↗
DOE OSTI2026

Two-mirror resonator for next-generation Compton gamma-ray source

The next-generation Compton gamma-ray sources (CGSs) based on storage rings require a high-power, well-focused laser beam as a photon driver, which can be realized using a Fabry-Perot cavity (FPC). In this work, we reexamine the behavior and performance of a two-mirror, nearly concentric resonator by introducing a new figure of merit representing the cavity’s proximity to instability. This figure of merit is used to analyze various aspects of the cavity design, including misalignment, beam coupling limitations, and beam size scaling. We then examine several factors affecting the gamma-ray flux, such as the interaction area, crossing angle for collision, frequency matching between the electron and laser beams, and intrabeam scattering effects. Using an example CGS, we demonstrate how to make improved design choices for a two-mirror resonator to enhance the gamma-ray beam flux. This work shows that simple two-mirror Fabry-Perot cavities are well suited as the laser driver for the next-generation storage ring-based CGS, while offering superior advantages in gamma-ray beam polarization control compared to more complex four-mirror, nonplanar resonators.

Delooze, Will↗
DOE OSTI2024

Ground observations of a space laser for the assessment of its in-orbit performance

The wind mission Aeolus of the European Space Agency was a groundbreaking achievement for Earth observation. Between 2018 and 2023, the space-borne lidar instrument ALADIN onboard the Aeolus satellite measured atmospheric wind profiles with global coverage, which contributed to improving the accuracy of numerical weather prediction. The precision of the wind observations, however, declined over the course of the mission due to a progressive loss of the atmospheric backscatter signal. The analysis of the root cause was supported by the Pierre Auger Observatory in Argentina whose fluorescence detector registered the ultraviolet laser pulses emitted from the instrument in space, thereby offering an estimation of the laser energy at the exit of the instrument for several days in 2019, 2020, and 2021. The reconstruction of the laser beam not only allowed for an independent assessment of the Aeolus performance, but also helped to improve the accuracy in the determination of the laser beam’s ground track on single pulse level. The results presented in this paper set a precedent for the monitoring of space lasers by ground-based telescopes and open new possibilities for the calibration of cosmic-ray observatories.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗