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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

Quantifying Trapped Powder in Electron Beam Powder Bed Fusion

Abstract Electron beam powder bed fusion (PBF-EB) shows great potential for manufacturing complex parts including those with internal cavities for heat exchanger, manifold systems, or energy absorption purposes. PBF-EB allows for the manufacture of channel geometries without the need for support structures. Due to the nature of the powder spreading process, powder feedstock is often trapped in intentionally manufactured cavities. This trapped powder can often be difficult to remove and can disturb the intended flow of fluid through the cavity or damage downstream components in its use case. These trapped powder particles present a risk of contamination and component failure if not completely evacuated. Ti6Al4V is a choice material for aerospace applications due to its high strength to weight ratio and its composition as a nonferrous metal; however, in weight sensitive applications excess entrapped powders or powders loosely attached to the surface could cause undesirable weight increases. The inherent spreading process of PBF-EB is different than laser powder bed fusion (PBF-LB) in its operational temperature, sintering. In addition, PBF-EB is less commonly studied in literature compared to its PBF-LB counterpart, and as a result the complexity of the semi-sintered powder and its spreading behavior are not well understood. Prior work has investigated the difficulty in removing trapped powder from PBF-EB, but these studies do not address how to quantify the amount of trapped powder in the cavity. Thus, an accurate method to measure the amount of trapped powder in the cavity must be investigated. In this work, Ti6Al4V coupons were manufactured with horizontal and vertical cavities of three different sizes. Archimedes testing allows for the determination of density differences caused by porosity and trapped powders by measuring mass and volumetric dispersion. Computed tomography (CT) is well suited for segmenting the internal structure and features of a part and has been studied for applications including voids, porosity, and dross. Thus, CT was explored as a method for evaluating trapped powder content in this work. The volumetric representation of the segmentation of the reconstructed CT volume can vary greatly depending on the input filter and thresholding methods. In this study, four different types of segmentation approaches were evaluated to determine the best approach for segmenting the volume as compared to an operator labeled ground truth. The percentage density results from the Archimedes testing were compared to the volumetric percent density from the computed tomography approach. Differences in packing density between two different internal channel features were investigated. Overall, this work sought to validate the use of computed tomography for the detection of trapped powders and present a framework for volumetric segmentation.

Johnstone, Brian↗
DOE OSTI2023

Progress on an Electron Beam Profile Monitor at the Fermilab Main Injector

The current program at Fermilab involves the construction of a new superconducting linear accelerator (LINAC) to replace the existing warm version. The new LINAC, together with other planned improvements, is in support of proton beam intensities in the Main Injector (MI) that will exceed 2 MW. Measuring the transverse profiles of these high intensity beams in a ring requires non-invasive techniques. The MI uses ionization profile monitors as its only profile system. An alternative technique involves measuring the deflection of a probe beam of electrons with a trajectory perpendicular to the proton beam. This type of device was installed in MI and initial studies of it have been previously presented. This paper will present the status and recent studies of the device utilizing different techniques.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Progress on an Electron Beam Profile Monitor at the Fermilab Main Injector

The current program at Fermilab involves the construction of a new superconducting linear accelerator (LINAC) to replace the existing warm version. The new LINAC, together with other planned improvements, is in support of proton beam intensities in the Main Injector (MI) that will exceed 2 MW. Measuring the transverse profiles of these high intensity beams in a ring requires non-invasive techniques. The MI uses ionization profile monitors as its only profile system. An alternative technique involves measuring the deflection of a probe beam of electrons with a trajectory perpendicular to the proton beam. This type of device was installed in MI and initial studies of it have been previously presented. This paper will present the status and recent studies of the device utilizing different techniques.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Electron beam characterization via quantum coherent optical magnetometry

We present a quantum optics-based detection method for determining the position and current of an electron beam. As electrons pass through a dilute vapor of rubidium atoms, their magnetic field perturbs the atomic spin's quantum state and causes polarization rotation of a laser resonant with an optical transition of the atoms. By measuring the polarization rotation angle across the laser beam, we recreate a 2D projection of the magnetic field and use it to determine the e-beam position, size, and total current. We tested this method for an e-beam with currents ranging from 30 to 110 μA. Our approach is insensitive to electron kinetic energy, and we confirmed that experimentally between 10 and 20 keV. In conclusion, this technique offers a unique platform for noninvasive characterization of charged particle beams used in accelerators for particle and nuclear physics research.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Fast Scanning Diamond Detector for Electron Beam Profile Monitoring

The first prototype of a fast scanning diamond beam profile detector (DBPD) suitable for invasive high power CW electron beam core profile measurements in transmittance mode was developed. It consists of a multi-strip solid state diamond detector to scan with high speed (up to 1 m/s) and precision (about 5 μm) through the core of an electron beam. The diamond sensor was made from a thin polycrystalline diamond (PCD) plate with highly B-doped diamond conductive strips both grown by CVD. Transient currents from the multi-strip detector were measured with fast digitizing electrometers. Successful operation of the DBPD was demonstrated for pulsed (5 Hz) and CW (78 kHz) CeC beams, including the detector’s ability to withstand a 20 sec insertion into the CW CeC beam core. The X-Y beam spatial profile was measured in one scan. Thermal modelling demonstrated a manageable thermal impact even from a relatively long insertion of the diamond sensor into the CW CeC core and very short (0.2 s) insertion into the CW LEReC beam core. Electrical impedance modelling of the detector and vacuum chamber assembly demonstrated minimal impact on beam line impedance with diamond sensor insertion.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Commissioning of Extended Electron Beam Ion Source at Brookhaven National Laboratory

Here, the Extended Electron Beam Ion Source (EEBIS) has been installed and commissioned at Brookhaven National Laboratory (BNL) hadron accelerator complex in the spring of 2023. EEBIS has replaced its predecessor, RhicEBIS, which provided ions for BNL hadron facilities for over a decade since 2009. The motivations for the source upgrade are to provide higher intensities of the Au 32+ ion beam for the Relativistic Heavy Ion Collider (RHIC) and to provide of an intense source of polarized 3 He 2+ ions for the future Electron Ion Collider (EIC) at BNL. EEBIS is and will continue to be the primary source for a variety of different ion species for the NASA Space Radiation Laboratory (NSRL) at BNL. EEBIS utilizes two identical, two-meter-long unshielded 5T warm bore superconducting solenoids, and it is operated with electron beam current up to 10 A, providing a high-capacity ion traps to fulfill the requirement for high intensity ion beams. The upstream solenoid contains a “short ion trap” with a length of 95 cm, while the “long ion trap” with a length of 178 cm is located inside the downstream solenoid bore. The main features of EEBIS are: * A Gas injection and ionization cell equipped with a Lorenz pulse valve * High-capacity ZAO non-evaporable getter (NEG) custom linear pumping units * In situ apparatus for pumping speed measurements to monitor NEG activation and saturation * “External drift tube” construction with differential pumping stages to provide space for Lorentz pulse valve and 3 He high-field polarization cell * A Ba oxide electron gun cathode. The design of EEBIS as well as the results of its commissioning and first-year operation are presented and discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

The effects of pre-plasma scale length on the relativistic electron beam directionality

The effects of pre-plasmas on the electron beam directionality was experimentally and numerically investigated. Single material and layered targets made of Ti and/or CH were used to simultaneously measure high-energy (≥3 MeV) electrons along two directions, pre-pulse energy and pre-plasma density. The electron directionality is quantified by using a new parameter, the electron energy ratio of the total kinetic energies along the two directions. Measurements and radiation–hydrodynamic (RH) simulations show that a large (≥3.5 μm) plasma scale length at the critical surface enhances electrons along the laser axis, and such pre-plasma conditions could only be achieved with the CH targets. Particle-in-cell simulations were performed on the RH generated pre-plasmas from Ti and CH targets, and the results show that the CH target provided conditions for higher forward momentum gains by electrons. First, the CH target allowed longer distances for electrons to interact with laser. Second, the intense laser pulse modified the critical surface, but the resulting surface differed. The CH target resulted in a smooth surface where a retro-reflection was observed while the Ti target resulted in a rippled surface that scattered the reflected light. As results, the CH electrons gained higher forward momentum via a direct-laser-acceleration in the counter propagating laser fields. So the results presented in this article show a way of controlling the high-energy electron directionality.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Nanometer-scale prebunched electron beams generated from all-optical plasma-based acceleration

High-quality and prebunched electron beams can produce coherent x-rays with high intensity and narrow bandwidth, which are essential for modern light sources. An all-optical scheme based on plasma-based acceleration for producing bright electron beams that are prebunched on the nanometer scale is proposed. By using a density modulation created by two low intensity counterpropagating lasers, the phase velocity of the plasma wake excited by an intense driver laser in a uniform plasma can be modulated at a frequency twice that of the colliding lasers, thus turning the injection on and off. The injected electrons are microbunched at the Doppler-shifted modulated wavelength, corresponding to the phase velocity of the gradually expanding wakefield. It is demonstrated that by controlling the properties of the drive and colliding lasers, beams with exotic prebunched structures can be produced, which may have critical applications in ultrafast high power x-rays. This extremely compact, all-optical scheme for producing ultrabright prebunched electron beams may therefore enable novel applications for ultrafast x-ray users and arouse general interest in various fields.

Beam injection, extraction & transport↗
DOE OSTI2020

A compact, high resolution energy, and emittance diagnostic for electron beams using active plasma lenses

High-resolution (sub-%), single-shot energy distribution, and emittance measurements of GeV-class electron beams generated by laser plasma accelerators (LPAs) have been enabled through the use of an active plasma lens combined with relatively short dipole magnets. This setup, with only 60 cm between the LPA source and the final diagnostic screen, was facilitated through the use of a replenishable ∼20–40 nm thick liquid crystal plasma mirror to separate remnant laser radiation from the electron beam without emittance degradation. As LPAs capable of generating GeV-class electron beams at cm-scale distances become increasingly ubiquitous, there is a need to supplement these compact accelerators with equally compact diagnostics.

Barber, S. K. (ORCID:0000000172518755)↗
DOE OSTI2024

Resistive hose modes in tokamak runaway electron beams

Beams of energetic runaway electrons are generated during disruptions in tokamaks, and fluid models are used to study their effects on macroscale dynamics. Linear computations of a massless, runaway electron beam coupled to MHD plasma show that resistive hose instabilities grow faster than tearing modes at large resistivity. Eigenvalue results with reduced models of the resistive hose instability are compared with results from the full MHD and beam system, showing that the resistive hose decouples from any plasma response. An estimate of plasma temperature at which growth of the resistive hose dominates tearing for post-disruption DIII-D plasma parameters is in a physically relevant regime.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Power density calculation of spontaneous radiation emission from a finite emittance electron beam in planar undulators

We extend the angular power density formulae for spontaneous radiation emission from planar undulators to include finite emittance and angular misalignment of the electron beam. Then we calculate and compare power densities estimated from integral approach with Gaussian beam distribution and summation approach with macro-particle allocation covering particle beam phase space. After showing that both approaches converge to each other, we apply the macro-particle approach to study power absorbed and transmitted by various apertures at front end of 9-ID beamline at National Synchrotron Light Source-II for misaligned electron beam. Our analysis indicate that the electron beam misalignment could lead to unwarranted power deposition at tighter apertures that would have been otherwise difficult to account for during the aperture design/choice process.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Power Density Distributions in Electron Beams

Measuring and controlling the power density distribution of electron beams used for welding is critical for producing repeatable welds and for transferring welding parameters between different machines. On any given machine, the power density distribution is controlled by defocusing the beam relative to its sharpest focused condition. However, measuring the power density distribution can be difficult due to the intense nature of welding beams and is further complicated by imperfect electron optics that can distort the beam, making it difficult to quantify. The enhanced modified Faraday cup (EMFC) diagnostic method was used here for beam analysis that utilizes computed tomography to reconstruct the beam’s power density distribution. These results were compared to the International Standards Organization (ISO) method for characterizing laser beams using a second-moment D4σ calculation. For ideal Gaussian-shaped beams, both methods would give the same result. However, for imperfect beams, the calculated D4σ diameter was shown to be about 25% larger relative to the FWe2 diameter measured by the EMFC due to the heavier weighting of data in the tails of the beam by D4σ. Finally, although both methods produce repeatable welds, it is important to understand the differences in the reported beam diameters, divergence angles, and beam parameter products when transferring parameters between machines.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Roadmap to an electron beam or X-ray center for industrial applications

Here, this paper introduces the topics that need consideration to allow an effective feasibility analysis of electron beams and/or X-rays technologies prior to potential investment and implementation of these technologies for industrial applications. It also highlights considerations for planning, developing and construction of an electron beam or X-ray facility The focus of this paper is on business topics and it provides details of where additional technical information can be found. The paper also describes current applications for electron beam and X-ray technologies to demonstrate their potential.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Steering an intense relativistic electron beam in a linear induction accelerator

The best electron beam transport through a linear induction accelerator (LIA) is achieved when the beam is well centered on the magnetic axis of the focusing solenoids. Since the beam may be injected offset from, or at an angle to, the centerline, dipole magnets are usually provided as a means to steer the beam and center it. Steering may be accomplished by trial and error, but this is very time consuming, especially for accelerators with a low repetition rate for beam position measurements and dipole adjustments. With this in mind, this article presents a steering method requiring a minimal number of measurements and adjustments to position the beam at any desired location, including positioning on the centerline.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Design and testing of a high perveance sheet beam electron gun

This paper presents the design, prototype engineering, and initial testing of a relatively low-voltage, high aspect ratio electron gun for versatile pulsed power applications. The sheet beam, diode electron gun is designed for (23–25) kV voltage and 6 µA/V1.5, as is required for x-band klystron, as a part of a compact Klylac delivering electron beam energy in the MeV range. The gun prototype was engineered, built, and tested using a Scandinova M1-0.5 modulator. Beam loss on the anode aperture is evaluated from transient waveforms and equivalent circuit modeling.

Instruments & Instrumentation↗
DOE OSTI2024

Charge lifetime improvement of the Continuous Electron Beam Accelerator Facility photogun with a biased anode

GaAs photocathodes in dc high-voltage photoguns are highly susceptible to ion back-bombardment, which reduces the photocathode quantum efficiency and limits the useful operating lifetime for producing polarized electron beams. This paper demonstrates that applying a small positive bias to the photogun anode can significantly suppress ion back-bombardment and increase charge lifetime. This technique was studied extensively using the Continuous Electron Beam Accelerator Facility photogun, where highly polarized electron beams created using a strained-superlattice GaAs / GaAsP photocathode were used and charge lifetimes improved by almost a factor of 2. A new simulation code was developed to model ion production and tracking in order to better understand and explain the factors that led to the performance improvement. Results of the experiments and simulations are discussed in detail. Published by the American Physical Society 2024

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Review of metal-containing resists in electron beam lithography: perspectives for extreme ultraviolet patterning

Background: Metal-containing resists entered the mainstream semiconductor industry process flow to mitigate the low absorbance of extreme ultraviolet (EUV) radiation by thin films of organic resists that lead to poor sensitivity and their inability to handle rigors of development and etching conditions. Aim: The long and rich history of using metal-containing resists in electron beam lithography can offer interesting lessons, pointers, and insights to the relatively newcomer EUV lithography, which is slightly over a decade old. Approach: Electron beam lithography has been enjoying a considerable amount of freedom in the choice of resist materials for close to 50 years; especially the use of metal-containing resists to attain not only single digit nanometer resolution, higher sensitivity, and etch resistance but also lower line-edge roughness. Here, we make a comprehensive historical review of the progress made in the patterning of metal-containing resists in electron beam lithography and derive insights that can be potentially useful in EUV patterning. Perspectives: Small molecular weight resists are proven to be crucial for achieving higher resolution with low line-edge roughness. Simplifying process flow by reducing etch-stack-layers is conceivable with metal-containing resists, along with direct-patterning of functional materials for heterogeneous integration. Efficient contact hole patterning at tighter pitches may be incumbent on progress in positive-tone resist research.

77 NANOSCIENCE AND NANOTECHNOLOGY↗