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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 1,135 records · Page 63
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Topography of Impact Structures on the Northern Polar Cap of Mars

The north polar residual ice deposits of mars are thought to be relatively young, based on the reported lack of any fresh impact craters in Viking Orbiter images. A handful of possible impact features were identified, but available data were inconclusive. Determining the number and current topographic characteristics of any craters on the polar residual ice surface is important in constraining the surface age, relative importance of polar cap resurfacing processes and ice flow dynamics, and the role of the cap deposits in the global volatile and climate cycles. Subsequent image processing advances and new Mars Orbiter Laser Altimeter (MOLA) data in the north polar region are now a considerable aid in impact feature identification. This study reconsiders the abundant Viking high-resolution polar images along with the new altimetry data. We examine possible impact features, compare their topography with known mars high-latitude impact features, and use their morphology as a constraint on crater modification processes.

Sakimoto, S. E. H.↗
NASA NTRS2019

Investigating Additively Manufactured 17-4 PH for Structural Applications

17-4 is used regularly to manufacture force transducers particularly for wind tunnel testing. Such applications place demanding structural requirements on the transducers with static safety factors of 1.5 common and the potential for additional dynamic loads. Additive manufacturing (AM) of transducers is very appealing because of significant potential cost and time savings as well as increased design flexibility. This study looks at the processing of 17-4 powder using selective laser melting by two different facilities using their own best practices. Hot isostatic pressing (HIP) is used by both facilities as part of the thermomechanical processing following printing to explore whether it can improve the consistency of mechanical properties. Results revealed that HIP reduced average porosity of 17-4 parts and that the yield strength of parts following solutionization and aging met wrought material property targets. Strain to failure of one of the facilities parts was less than 5% compared to greater than 9% for the other facility. Inspection of failure surfaces revealed this discrepancy could be attributed to pores (2-4% area fraction) on the failure surface of the low ductility parts. Phase content varied between the facilities with one facility producing fully martensitic parts and the other containing some retained austenite. The phase content of the starting powder and a slower than air cooling rate following the final heat treatment above the austenite eutectoid temperature are likely sources of the retained austenite. Taken together these results suggest that the current state of the art in AM 17-4 processing is sufficient for many NASA force measurement applications, but that attention is required at each stage of processing to assure desired mechanical properties.

Burns, Devin E.↗
DOE OSTI2023

Effects of lead and lean in multi-axis directed energy deposition

Here, the present study examines the effect of varying laser incidence angles on textural, microstructural, and geometric characteristics of directed energy deposition (DED) processed materials, providing a more comprehensive outlook on participating laser-matter interaction phenomena and ultimately devising strategies to ameliorate print performance. In this study, single-layer, single-/multi-track specimens were processed to examine the effect of non-orthogonal angular configurations on bead morphology, microstructure, phase composition, and textural representation of DED-processed 316L stainless steel materials. It was observed that bead size decreased at increasing lead and lean angles. Asymmetry in the distribution of the bead morphology as a function of lead angle indicates better catchment for acute lead angle configurations over obtuse configurations. No significant differences in phase composition, texture, and microstructure were observed in moderate off-axis configurations. When the penetration depth for the deposits was below 20 μm, columnar structures dominated the microstructure of the deposited material. At deeper penetration depths, columnar and equiaxed structures were observed at the bead-substrate interface and center of the bead, respectively. Compared to powder-blown DED, wire-DED dilution profiles were found to be asymmetric in both orthogonal and non-orthogonal wire DED samples.

36 MATERIALS SCIENCE↗
NASA NTRS2001

Porosity and Variations in Microgravity Aerogel Nano-Structures: New Laser Speckle Characterization Methods - 2

The transition from sol to gel is a process that is critical to the properties of engineered nanomaterials, but one with few available techniques for observing the dynamic processes occurring during the evolution of the gel network. Specifically, the observation of various cluster aggregation models, such as diffusion-limited and reaction-limited cluster growth can be quite difficult. This can be rather important as the actual aggregation model can dramatically influence the mechanical properties of gels, and is significantly affected by the presence of convective flows, or their absence in microgravity. We have developed two new non-intrusive optical methods for observing the aggregation processes within gels in real time. These make use of the dynamic behavior of laser speckle patterns produced when an intense laser source is passed through a gelling sol. The first method is a simplified time-correlation measurement, where the speckle pattern is observed using a CCD camera and information on the movement of the scattering objects is readily apparent. This approach is extremely sensitive to minute variations in the flow field as the observed speckle pattern is a diffraction-based image, and is therefore sensitive to motions within the sol on the order of the wavelength of the probing light. Additionally, this method has proven useful in determining a precise time for the gel-point, an event often difficult to measure. Monitoring the evolution of contrast within the speckle field is another method that has proven useful for studying aeration. In this case, speckle contrast is dependent upon the size (correlation length) and number of scattering centers, increasing with increasing size, and decreasing with increasing numbers. The dynamic behavior of cluster growth in gels causes both of these to change simultaneously with time, the exact rate of which is determined by the specific aggregation model involved. Actual growth processes can now be observed, and the effects of varying gravity fields on the growth processes qualitatively described. Results on preliminary ground-based measurements have been obtained.

Hunt, A. J.↗
NASA NTRS1985

Laser Systems

Tunable diode lasers are employed as radiation sources in high resolution infrared spectroscopy to determine spectral characteristics of gaseous compounds. With other laser systems, they are produced by Spectra-Physics, and used to monitor chemical processes, monitor production of quantity halogen lamps, etc. The Laser Analytics Division of Spectra-Physics credits the system's reliability to a program funded by Langley in the 1970s. Company no longer U.S.-owned. 5/22/97

Source record↗
DOE OSTI2023

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Characterization of the Fusion Zone in Laser Beam Welds on SS304L

Designing a welded joint requires consideration of the welding process, component/assembly structure and weld geometry, material composition, properties, and desired joint performance. The designer must also specify a set of acceptance criteria used to evaluate the welds. This study was conducted to support the design team responsible for specifying the spot weld profile by investigating the relationship between weld process parameters and the weld geometry and properties to further inform design optimization. The subjects of this study are two thin stainless steel 304L (SS304L) components joined by Laser Beam Welding (LBW). The components are the Housing, which contains flexible circuitry, and the Cover that protects the circuitry during handling, installation, and under service loads. Figure 1 illustrates coupon versions of the Cover and Housing used to simulate the interface between these components for weld testing. These coupon representations of assembly components were designed to match the material and relevant geometry related to the welded joint while other features not relevant to the welded joint are excluded.The objective of this study was to characterize the sensitivity of the weld geometry and mechanical properties to the input weld parameters to inform further Finite Element Analysis (FEA) efforts in balancing joint strength against assembly deformation caused by the welding process. Characterization was accomplished by varying laser welding parameters around the current design values and measuring weld geometry on the cross-sections. Nanoindentation with a spherical and flat-ended tip was used on polished section cuts of the weld to obtain direct estimates of the stress-strain response of the Fusion Zone (FZ) for comparison to the Base Metal (BM).

42 ENGINEERING↗
DOE OSTI2023

Modeling and Simulation of Advanced Manufacturing Techniques using MOOSE and MALAMUTE

Advanced manufacturing techniques offer increased geometry complexity, energy and material usage efficiency improvements, and an expanded palette of materials as compared to conventional manufacturing approaches. Advanced-manufacturing-produced parts can experience wide variations in the final microstructure, and these microstructure variations significantly impact the parts’ performance. In this chapter, we present recent code developments within Multiphysics Object-Oriented Simulation Environment (MOOSE) and in the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE). Here we demonstrate applying these modeling and simulation codes to two advanced manufacturing process types: advanced sintering techniques and laser-based additive manufacturing techniques. The multiphysics and multiscale capabilities of these codes enable prediction of the microstructure evolution resulting from variations in the Advanced manufacturing process parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Method and device for a high temperature vacuum-safe solder resist utilizing laser ablation of solderable surfaces for an electronic module assembly

A process for manufacturing an electronic component having attaches includes providing a first component having a first attach, forming trenches on a portion of the first attach with a laser to form a solder stop, and providing a second component comprising a second attach. The process further includes providing solder between the first attach and the second attach to form a connection between the first component and the second component, where the trenches contain the solder to a usable area. A device produced by the process is disclosed as well.

Stabach, Jennifer↗
DOE OSTI2025

Laser Ablation for Low-Cost Multijunction III-V Solar Cell Mesa Isolations

Eliminating photolithography from solar cell processing is a significant opportunity for cost reduction for III-V solar cells. In this work, we test femtosecond laser ablation and scribing as an alternative to contact photolithography and wet chemical etching for mesa isolation, when processing multijunction cells. We demonstrate that upright multijunction solar cells isolated by using the laser as a scribe to cleave through the substrate had virtually no performance loss when compared to a baseline cell processed with photolithography. By contrast, cells isolated by laser ablating through the active layers have performance losses that cannot be fully eliminated with post-processing etches. This demonstration of photolithography-free mesa isolation with no performance losses is promising for less expensive III-V manufacturing.

14 SOLAR ENERGY↗
DOE OSTI2022

Stochastic exciton-scattering theory of optical line shapes: Renormalized many-body contributions

Spectral line shapes provide a window into the local environment coupled to a quantum transition in the condensed phase. In this paper, we build upon a stochastic model to account for non-stationary background processes produced by broad-band pulsed laser stimulation, as distinguished from those for stationary phonon bath. In particular, we consider the contribution of pair-fluctuations arising from the full bosonic many-body Hamiltonian within a mean-field approximation, treating the coupling to the system as a stochastic noise term. Herein, using the Itô transformation, we consider two limiting cases for our model, which lead to a connection between the observed spectral fluctuations and the spectral density of the environment. In the first case, we consider a Brownian environment and show that this produces spectral dynamics that relax to form dressed excitonic states and recover an Anderson–Kubo-like form for the spectral correlations. In the second case, we assume that the spectrum is Anderson–Kubo like and invert to determine the corresponding background. Using the Jensen inequality, we obtain an upper limit for the spectral density for the background. The results presented here provide the technical tools for applying the stochastic model to a broad range of problems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Novel Process for Screen-Printed Selective Area Front Polysilicon Contacts for TOPCon Cells Using Laser Oxidation

The efficiency potential of double-side tunnel oxide passivated contact (DS-TOPCon) solar cells is limited by parasitic absorption in the front poly-Si layer, despite excellent passivation and high V OC . The use of patterned poly-Si only under the front metal grid lines can significantly reduce the parasitic absorption loss without sacrificing voltage. In this work, we demonstrate a simple, manufacturing-friendly method of patterning the front poly-Si using a nanosecond UV (355 nm) laser. We found that with laser powers ≥3 W at a 400 mm/s scan speed, an estimated 1–4 nm thick stoichiometric SiO 2 layer was grown on TOPCon. This served as a mask for KOH-etching of 200 nm poly-Si, allowing for patterning of poly-Si fingers required for selective TOPCon. While laser powers above 3 W caused substantial deterioration in passivation quality, the resulting damage in J 0 was largely recovered by subsequent PECVD SiN x deposition. At 3 W, the full area J 0 was found to be 36.8 fA·cm –2 . Furthermore, this translates to 1.68 fA·cm –2 for 4.48% coverage from the wing area of the polyfinger lines (100 lines–100 μm wide and 30 μm metal) contributing to a total front J 0 of ~10 fA·cm –2 , well suited for 25% efficient solar cells

42 ENGINEERING↗
DOE OSTI2023

Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.

36 MATERIALS SCIENCE↗
DOE OSTI2020

System and method for in-process inspection within advanced manufacturing processes

A system and method can include a laser Doppler vibrometer (LDV) in optical communication with a part during manufacturing and a transducer in ultrasonic communication with the part during manufacturing. The system can also include a controller connected to both the LDV and the transducer. The controller may be configured to cause the transducer to vibrate the part during manufacturing at a predetermined frequency and the LDV may be configured to measure one or more mechanical response types of the part during manufacturing based on one or more optical characteristics of a reflected beam. The controller may further be configured to determine whether a defect is present in the part during manufacturing in response to the one or more mechanical response types of the part.

42 ENGINEERING↗
DOE OSTI2025

Direct measurements for the kinetics of C–C bond fission in the high temperature decomposition of isopropanol

The thermal decomposition of isopropanol was studied experimentally and theoretically with a view to isolate and directly measure rate coefficients for the dominant radical channel in this multi-channel process. Two complementary shock tube methods, laser schlieren densitomtery and H-atom atomic resonance absorption spectroscopy, were used to obtain rate coefficents for the C–C bond fission channel. The experimental ranges span temperatures from 1200–2100 K and pressures between 30–690 torr. These are the most direct measurements of this rate coefficent in the fall-off regime of relevance to high-temperature reacting systems. Theoretical studies also performed in this work confirm that the title reaction and a molecular elimination involving dehydration were the sole unimolecular processes at high temperatures. A master equation analysis yielded k ( T, P ) for the C–C fission and these are shown to be in good agreement with the present experimental measurements. Comparisons with prior experimental and theoretical studies in the literature indicate branching ratios as well as absolute k ( T, P ) for C–C bond-fission have been under-predicted for this decomposition reaction. Consequently, results from the present studies place an increased emphasis on radical-driven secondary processes in high-temperature pyrolysis of this simplest secondary alcohol.

Kim, John H. [Univ. of Michigan, Ann Arbor, MI (Un↗
DOE OSTI2022

Electron Weibel instability induced magnetic fields in optical-field ionized plasmas

Generation and amplification of magnetic fields in plasmas is a long-standing topic that is of great interest to both plasma and space physics. The electron Weibel instability is a well-known mechanism responsible for self-generating magnetic fields in plasmas with temperature anisotropy and has been extensively investigated in both theory and simulations, yet experimental verification of this instability has been challenging. Recently, we demonstrated a new experimental platform that enables controlled initialization of highly nonthermal and/or anisotropic plasma electron velocity distributions via optical-field ionization. Using an external electron probe bunch from a linear accelerator, the onset, saturation, and decay of the self-generated magnetic fields due to electron Weibel instability were measured for the first time to our knowledge. In this paper, we will first present experimental results on time-resolved measurements of the Weibel magnetic fields in non-relativistic plasmas produced by Ti:Sapphire laser pulses (0.8 μm) and then discuss the feasibility of extending the study to a quasi-relativistic regime by using intense CO 2 (e.g., 9.2 μm) lasers to produce much hotter plasmas.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Observation of intense Stokes and anti-Stokes lines in CH4 pumped by 355 nm of a Nd:YAG laser

The stimulated Raman scattering (SRS) and four-wave mixing (FWM) processes are studied in detail in CH4 gas pumped by the third-harmonic of Nd:YAG laser at 355 nm. The conversion efficiency and average output energy are measured for the various Stokes and anti-Stokes lines at different experimental conditions. The threshold input energy at various CH4 pressures is calculated for the unguided and capillary waveguide Raman cells. The calculated values for the capillary case are compared with the measured values at different CH4 pressures and the two results are in good agreement.

Sentrayan, K.↗