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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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Use of laser range finders and range image analysis in automated assembly tasks
A proposition to study the effect of filtering processes on range images and to evaluate the performance of two different laser range mappers is made. Median filtering was utilized to remove noise from the range images. First and second order derivatives are then utilized to locate the similarities and dissimilarities between the processed and the original images. Range depth information is converted into spatial coordinates, and a set of coefficients which describe 3-D objects is generated using the algorithm developed in the second phase of this research. Range images of spheres and cylinders are used for experimental purposes. An algorithm was developed to compare the performance of two different laser range mappers based upon the range depth information of surfaces generated by each of the mappers. Furthermore, an approach based on 2-D analytic geometry is also proposed which serves as a basis for the recognition of regular 3-D geometric objects.
Helium tribology of Inconel 617 subjected to laser peening for high temperature nuclear reactor applications
Inconel 617 is among the best candidates for utilization in high temperature gas cooled reactor tribo-components. However, the combined effects of sliding contact, along with intermittent idle times and very high temperature material degradation, deteriorates the alloy tribological performance, especially under a helium atmosphere. Laser peening is a surface treatment technique which can enhance the properties at the surface and subsurface by generating deep residual stresses and enhanced microstructure. In this work, we report the tribological behavior of regular laser peened as well as thermally-engineered laser peened Inconel 617 under helium and air atmospheres at 800 °C. In addition to friction and wear studies, the specimens are characterized by different analytical techniques to further understand the mechanisms involved in the peening process and sliding contact. Regardless of the peening process and post-process treatment types, it is observed that laser peening improves the tribological characteristics of Inconel 617. Interestingly, laser peening followed by helium thermal aging shows highly enhanced tribological behavior. This is attributed to the strengthening effect of the laser peening on the surface oxides providing an excellent and lasting protective and lubricating film under helium exposure.
Particle and flow field measurements by laser holography
Holograms make transmission recordings of aerodynamic events which are real-illuminated with ground-glass light diffusers and with no requirements for precision. The three-dimensional interferograms can be recorded by stored-beam, double-exposure, and double-plate techniques. Weak traveling shock waves, generated by rotating blade rows of an aircraft fan compressor, can be visualized by rapid double-exposure holograms recorded with a ruby laser. The same laser technique can also determine flow velocities from holograms of small flow-entrained particles. Particles larger than one-quarter millimeter are recorded under rear diffuse illumination conditions. Smaller particles can be recorded by their own forward scattering of laser light through the sensitivity of the holographic process for weak signals. Since the holographic apparatus can be path-matched, both particle and flow interferograms can be recorded with lasers of short coherence length.
In Situ Geochemical Analysis and Age Dating of Rocks Using Laser Ablation-Miniature Mass Spectrometer
A miniaturized instrument for performing chemical and isotopic analysis of rocks has been developed. The rock sample is ablated by a laser and the neutral species produced are analyzed using the JPL-invented miniature mass spectrometer. The direct sampling of neutral ablated material and the simultaneous measurement of all the elemental and isotopic species are the novelties of this method. In this laser ablation-miniature mass spectrometer (LA-MMS) method, the ablated neutral atoms are led into the electron impact ionization source of the MMS, where they are ionized by a 70-eV electron beam. This results in a secondary ion pulse typically 10-100 microsecond wide, compared to the original 5-10-nanosecond laser pulse duration. Ions of different masses are then spatially dispersed along the focal plane of the magnetic sector of the miniature mass spectrometer and measured in parallel by a modified CCD (charge-coupled device) array detector capable of detecting ions directly. Compared to conventional scanning techniques, simultaneous measurement of the ion pulse along the focal plane effectively offers a 100% duty cycle over a wide mass range. LAMMS offers a more quantitative assessment of elemental composition than techniques that detect laser-ionized species produced directly in the ablation process because the latter can be strongly influenced by matrix effects that vary with the structure and geometry of the surface, the laser beam, and the ionization energies of the elements. The measurement of high-precision isotopic ratios and elemental composition of different rock minerals by LAMMS method has been demonstrated. The LA-MMS can be applied for the absolute age determination of rocks. There is no such instrument available presently in a miniaturized version that can be used for NASA space missions. Work is in progress in the laboratory for geochronology of rocks using LA-MMS that is based on K-Ar radiogenic dating technique.
Indirect Liftoff Mechanism for High‐Throughput, Single‐Source Laser Scribing for Perovskite Solar Modules
A high‐throughput, single‐source laser scribing method exploiting a transparent conducting oxide (TCO) indirect liftoff mechanism is developed to produce serially interconnected perovskite solar modules. The TCO‐based indirect liftoff mechanism relies solely on laser absorption in the front transparent electrode material reducing thermal damage to the overlying layers and allowing for fast scribing speeds with low‐cost μs‐pulse duration fiber laser systems. Minimal resistive power losses are observed with the method compared to conventional ablative laser scribes, maintaining the power conversion efficiencies of small‐area devices (≈0.2 cm 2 ) across significantly larger deposition areas (≈1 cm 2 ). Finally, demonstrating > 3 m s −1 processing speeds, TCO‐based liftoff provides the highest throughput laser scribing method for thin‐film photovoltaic devices produced on glass/TCO substrates, capable of processing large‐area perovskite solar modules at a manufacturing scale.
Depth-Resolved X-Ray Nanoimaging of Coherent and Incoherent Energy Transport in Silicon Carbide
Understanding lattice dynamics is crucial for optimizing the process of creating functional structures, such as laser writing of color-center defects. However, existing structural probes have difficulty measuring structural dynamics with submicrometer depth sensitivity. Here, in this study, a depth-resolved ultrafast X-ray nanodiffraction technique is developed to track the lattice dynamics of silicon carbide (SiC) in three dimensions. Upon laser excitation of an aluminum layer that acts as a heat and strain transducer, a specular Bragg peak of SiC shows an overall increase in the X-ray diffraction intensity rather than a peak shift. The relaxation dynamics of the increased intensity are significantly different when probed on and off the Bragg peak. The fast subnanosecond relaxation probed at the maximum of the Bragg peak is a result of the propagation of a coherent strain wave along the depth direction, while a slow relaxation probed at the wings of the Bragg peak reflects a localized incoherent lattice heating. To further visualize these processes, spatiotemporal maps were obtained by scanning the relative position and delay between the laser pump and X-ray probe beams, which capture the propagation of the strain wave, as well as a stationary structural distortion close to the aluminum/SiC interface. These depth-resolved structural measurements disentangle energy dissipation mechanisms in laser-excited SiC, and they open opportunities for finer control of, for example, the formation of optically addressable defect complexes central to quantum information applications.
Nanoscale ultrafast lattice modulation with a free-electron laser
Ultrafast optical laser-based techniques have enabled the probing of atomistic processes at their intrinsic temporal scales with femto- and attosecond resolution. However, the long wavelengths of optical lasers have prevented their interrogation and manipulation with nanoscale spatial specificity. Advances in hard X-ray free-electron lasers have enabled progress in developing X-ray transient-grating spectroscopy, a technique that aims to coherently control elementary excitations with nanoscale X-ray standing waves. Thus far, the realization of this technique at the nanoscale has been a challenge. Here we demonstrate X-ray transient-grating spectroscopy with spatial periods of the order of 10 nm via the subfemtosecond synchronization of two hard X-ray pump pulses at a precisely controlled crossing angle. This creates a thermal grating and preferentially excites coherent longitudinal acoustic phonon modes with the transient-grating wavevector. On probing with a third, variably delayed, X-ray pulse with the same photon energy, time-and-wavevector-resolved measurements of the modulation of the induced scattering intensity provide evidence of ballistic thermal transport at nanometre scales. Finally, these results highlight the potential of X-ray transient gratings as a powerful platform for studying nanoscale transport in condensed matter and the coherent control of nanoscale dynamics.
Control Method for Video Guidance Sensor System
A method is provided for controlling operations in a video guidance sensor system wherein images of laser output signals transmitted by the system and returned from a target are captured and processed by the system to produce data used in tracking of the target. Six modes of operation are provided as follows: (i) a reset mode; (ii) a diagnostic mode; (iii) a standby mode; (iv) an acquisition mode; (v) a tracking mode; and (vi) a spot mode wherein captured images of returned laser signals are processed to produce data for all spots found in the image. The method provides for automatic transition to the standby mode from the reset mode after integrity checks are performed and from the diagnostic mode to the reset mode after diagnostic operations are commands is permitted only when the system is in the carried out. Further, acceptance of reset and diagnostic standby mode. The method also provides for automatic transition from the acquisition mode to the tracking mode when an acceptable target is found.
Control method for video guidance sensor system
A method is provided for controlling operations in a video guidance sensor system wherein images of laser output signals transmitted by the system and returned from a target are captured and processed by the system to produce data used in tracking of the target. Six modes of operation are provided as follows: (i) a reset mode; (ii) a diagnostic mode; (iii) a standby mode; (iv) an acquisition mode; (v) a tracking mode; and (vi) a spot mode wherein captured images of returned laser signals are processed to produce data for all spots found in the image. The method provides for automatic transition to the standby mode from the reset mode after integrity checks are performed and from the diagnostic mode to the reset mode after diagnostic operations are carried out. Further, acceptance of reset and diagnostic commands is permitted only when the system is in the standby mode. The method also provides for automatic transition from the acquisition mode to the tracking mode when an acceptable target is found.
High fidelity model of directed energy deposition: Laser-powder-melt pool interaction and effect of laser beam profile on solidification microstructure
Metal additive manufacturing technologies keep receiving a great deal of interest as well as strong requests to develop methods to link the process science to printed parts performance and understand how to overcome inherent limitations. Here, a high-fidelity model based on the multiphysics ALE3D code was developed to reproduce the directed energy deposition process down to the powder scale. This includes resolving the laser-powder-melt pool interactions (powder impingement and incorporation into melt pool, hydrodynamics flow condition and laser absorption inefficiencies) as well as the resulting solidification microstructure. This micrometer scale digital twin captured the effect of powder incorporation process and powder flow rate on porosity. Furthermore, it was used to explore how a ring laser beam profile instead of the standard Gaussian laser profile could decrease the thermal gradient along the solidification front in the melt pool, which in turn can increase propensity for more desirable equiaxed grains.
Defect And Damage Characterization Of Additively Manufactured Titanium Alloy Ti-5553 Using Traditional Computed Tomography Volume Segmentation And Machine Learning Algorithms
The mechanical response of a component is affected by defects, such as porosity, arising from the laser powder bed fusion (LPBF) fabrication process. Thus, it is important to develop accurate and efficient inspection methods for identifying porosity. In this work, porosity identified in an X-ray computed tomography (XCT) volume of a Ti-5553 coupon was compared to pores identified in a serial sectioned volume that represented the ground truth. The porosity of the XCT scan was identified using contrast-based, ISO-based, and machine learning (ML) methods for segmentation. Large inherent porosity was easy to identify, but the ISO thresholding still struggled due to the intensity gradient resulting from both the beam hardening in XCT and the uneven lighting of the serial sectioning panels. Further, the results show that ML-based methods were better suited for identifying small pores and reducing the amount of false positives. Additionally, high strain-rate impact testing was done on some of the XCT samples as well as post-mortem XCT inspection, and the same suite of segmentation and quantification tools were used to identify the large spallation cavities. The comparison of porosity pre- and post-mortem provides insight on the influence of the LPBF porosity on the formation of spall cavities.
Design of the high-yield time-gated x-ray hot-spot imager for OMEGA
Time-resolved x-ray self-emission imaging of hot spots in inertial confinement fusion experiments along several lines of sight provides critical information on the pressure and the transient morphology of the hot spot on the University of Rochester’s OMEGA Laser System. At least three quasi-orthogonal lines of sight are required to infer the tomographic information of the hot spots of deuterium–tritium cryogenic layered implosions. OMEGA currently has two time-gated x-ray hot-spot imagers: the time-resolved Kirkpatrick–Baez x-ray microscope and the single-line-of-sight, time-resolved x-ray imager (SLOS-TRXI). The time-gated x-ray hot-spot imager (XRHSI) is being developed for use on OMEGA as the third line of sight for the high-yield operation of up to 4 × 10 14 neutrons. XRHSI follows the SLOS-TRXI concept; however, it will have improved spatial and temporal resolutions of 5 μm and 20 ps, respectively. The simultaneous operation of the three instruments will provide 3-D reconstructions of the assembled hot-spot fuel at various times through peak thermonuclear output. The technical approach consists of a pinhole array imager and demagnifying time-dilation drift tube that are coupled to two side-by-side hybrid complementary metal–oxide semiconductor (hCMOS) image sensors. To minimize the background and to harden the diagnostics, an angled drift-tube assembly shifting the hCMOS sensors out of the direct line of sight and neutron shielding will be applied. As a result, the technical design space for the instrument will be discussed and the conceptual design will be presented.
Coupling to rotational manifolds to improve gas-phase pump–probe spectroscopic models
The physical picture of gas-phase optical transitions is normally presented as an isolated two-level system balanced by upward and downward processes. Isolated models assume a phenomenological treatment of collisional dephasing but do not strictly account for collisional population exchange with the rotational baths. While this assumption is valid under low-intensity conditions, where excitation is rate-limiting, isolated models can deviate from Beer’s Law at sufficient pressures and monochromatic intensities when both collisional broadening and power broadening are comparable to (or greater than) lifetime broadening, which are not uncommon conditions for cavity enhanced spectroscopies in the mid-IR spectral range. Although this problem has been addressed by rate-equation models for linear absorption measurements, a general treatment for multi-level quantum mechanical models suitable for non-linear absorption measurements (two-photon/two-color/pump–probe) is lacking. Isolated models require physical parameter inputs that disagree with expected values by at least an order of magnitude. These non-physical models undermine the ability to predict non-linear signal strengths under untested conditions and thereby limit the potential to optimize the sensitivity of non-linear spectroscopies and to expand their analytical applications (e.g., new analytes and/or buffer gases, changes in cavity free-spectral-range, changes in intracavity powers or wavelengths, and accurate investigation of physical phenomena). In this study, we derive bath-coupled models for gaseous pump–probe spectroscopy by application of the quantum Lindblad equation and detailed balance. Bath-coupled models are shown to fit data consistently across variations in intensity and agree with all physically expected values.
Controlled Contamination of Epoxy Composites with PDMS and Removal by Laser Ablation
Surface preparation is critical to the performance of adhesively bonded composites. During manufacturing, minute quantities of mold release compounds are inevitably deposited on faying surfaces and may compromise bond performance. To ensure safety, mechanical fasteners and other crack arrest features must be installed in the bondlines of primary structures, which negates some advantages of adhesively bonded construction. Laser ablation is an automated, repeatable, and scalable process with high potential for the surface preparation of metals and composites in critical applications such as primary airframe structures. In this study, laser ablation is evaluated on composite surfaces for the removal of polydimethylsiloxane (PDMS), a common mold release material. Composite panels were contaminated uniformly with PDMS film thicknesses as low as 6.0 nm as measured by variable angle spectroscopic ellipsometry. Bond performance was assessed by mechanical testing using a 250 F cure, epoxy adhesive and compared with pre-bond surface inspection results. Water contact angle, optically stimulated electron emission, and laser induced breakdown spectroscopy were used to characterize contaminated and laser ablated surfaces. The failure mode obtained from double cantilever beam tests correlated well with surface characterization data. The test results indicated that even low levels of PDMS were not completely removed by laser ablation.
Particle Beam Acceleration Using 3 Petawatt Laser Pulses
The Zettawatt-Equivalent Ultrashort pulse laser System (ZEUS) is presently operational at the Gerard Mourou Center for Ultrafast Optical Science (CUOS) at the University of Michigan. ZEUS is a significant upgrade of the previous high power laser systems at CUOS and consists of two beamlines thatoperate in perfect synchronization. The 500 TW beamline became operational in 2023, 2 PW operation started in 2025 and full 3 PW power levels will be available in 2026. It is presently the highest power laser system in the US. In this grant the high field science group at CUOS has leveraged this unique high power laser facility to investigate laser wake field acceleration (LWFA) in ultra-high power laser plasma interactions and have shown how this can scale for future electron–positron colliders at high energy. The dual beam experimental configuration enables flexibility for many frontier experiments in laser-driven acceleration research, in particular, enabling extended channelling/acceleration experiments, positron generation/acceleration experiments and proof-of-principle transverse pumping “dephasingless” electron acceleration experiment and theory. LWFA may be able to miniaturize particle accelerators for high energy physics and also enable new sources of ultrafast, extreme brightness and precise x-rays for a wide variety of applications. In laser wake field acceleration, an electron bunch “surfs” on the electron plasma wave (the “wake field”) generated by the ponderomotive force of an intense laser. The plasma wave has a strong longitudinal electric field that stays in phase with the relativistic driver. A relativistic charged particle may, therefore, remain in phase with the accelerating field over long distances and gain ultra-relativistic energies. The accelerating electric field strength that the plasma wave can support can be many orders of magnitude higher than that of conventional accelerators, which makes laser wakefield acceleration an exciting prospect as an advanced accelerator concept. In this research project we have investigated the scaling of this mechanism to laser powers of 2 PW and have measured the x-ray emission and radio frequency emission resulting from the acceleration process. We have also performed theoretical investigation of mechanisms to scale laser driven accelerators to much higher energy using dephasingless acceleration processes.
Hybrid Al Casting + AM Components for Automotive Applications
Although casting Aluminum (Al) alloys is widely used for automotive application, the conventional casting process is showing limitations for modern vehicle production. A hybrid manufacturing method that is capable of fabricating automotive structures with tailored functionality and tuned attributes at a high production rate is proposed in this project, utilizing the merits of conventional casting methods and additive manufacturing (AM) methods. Ford is interested in supplementing conventional casting processes (e.g., shape casting, high pressure die casting) with local modifications to geometry and microstructure using additive manufacturing techniques. Two additive manufacturing methods, wire-arc and laser hot-wire directed energy deposition AM process, were evaluated by deposition of 4043 filler wire onto high-pressure die cast and permanent mold cast Al-Si alloys. The feasibility of this hybrid manufacturing method was determined through trial deposition and evaluation of defects, microstructure, and mechanical properties. Laser hot-wire deposition was found to be beneficial for this application with low porosity, a refined microstructure, and mechanical properties similar to those reported in the literature for 4043. The mechanical properties of the interface between the A356 casting and deposited 4043 were found to be controlled by the weaker deposit material.
Review of laser-solid interaction and its possibilities for space propulsion
Literature on laser-solid interaction is surveyed and the important regimes of this process are delineated. This information is used to discuss the possibility of a laser induced ablation thruster. It is concluded that such a thruster may be feasible if a sufficiently high intensity, high frequency laser beam is available and that further study of interaction is needed.