Results for “laser processing” — Page 70

DOE OSTI2023

Experimental and computational investigation into the hydrodynamics and chemical dynamics of laser ablation aluminum plasmas

Laser ablation plasma chemistry is governed by a complex interplay between hydrodynamic plasma-gas mixing processes, thermodynamics, and rapid high-temperature chemical reactions. Here, in this work, we investigate the gas-phase oxidation chemistry of ns-laser ablation aluminum plasmas in air using optical spectroscopy combined with advanced multi-physics modeling. Experimental measurements demonstrate the formation of AlO in the plasma plume as early as 1 μs while computational results reveal that several Al x O y species are distributed in the periphery of the plume at even earlier times (<20 ns) in the presence of large temperature gradients and strong shockwaves. Interactions with the ablation crater during rapid plume expansion are shown to initiate vortex formation, followed by mixing dynamics that work to pull AlO into the vortices to react with gas-phase Al to form Al 2 O. Oxygen and several aluminum oxides are simultaneously pulled up through the stem of the fireball, encouraging further intermixing between reacting species and enhanced molecular formation. This work concludes that chemical dynamics in laser ablation plasmas is driven by diffusion processes, concentration gradients, and plume hydrodynamics while strong shockwaves generated during laser ablation do not impede chemical reactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2003

Validating NASA's Airborne Multikilohertz Microlaser Altimeter (Microaltimeter) by Direct Comparison of Data Taken Over Ocean City, Maryland Against an Existing Digital Elevation Model

NASA's Airborne Multikilohertz Microlaser Altimeter (Microaltimeter) is a scanning, photon-counting laser altimeter, which uses a low energy (less than 10 microJuoles), high repetition rate (approximately 10 kHz) laser, transmitting at 532 nm. A 14 cm diameter telescope images the ground return onto a segmented anode photomultiplier, which provides up to 16 range returns for each fire. Multiple engineering flights were made during 2001 and 2002 over the Maryland and Virginia coastal area, all during daylight hours. Post-processing of the data to geolocate the laser footprint and determine the terrain height requires post- detection Poisson filtering techniques to extract the actual ground returns from the noise. Validation of the instrument's ability to produce accurate terrain heights will be accomplished by direct comparison of data taken over Ocean City, Maryland with a Digital Elevation Model (DEM) of the region produced at Ohio State University (OSU) from other laser altimeter and photographic sources. The techniques employed to produce terrain heights from the Microaltimeter ranges will be shown, along with some preliminary comparisons with the OSU DEM.

Abel, Peter↗

NASA NTRS1983

Containerless high temperature property measurements by atomic fluorescence

The use of laser induced fluorescence (LIF) techniques for containerless study of high temperature processes and material properties is studied. Gas jet and electromagnetic levitation and electromagnetic and laser heating techniques are used with LIF in Earth-based containerless high temperature experiments. The work to date includes development of an apparatus and its use in studies of chemical reactions on Al2O3, molybdenum, and tungsten specimens, novel methods for noncontact specimen temperature measurement, and levitation jet properties. Brief summaries of these studies are given. The apparatus is described and detailed results for the current reporting period are presented.

Source record↗

NASA NTRS1984

Containerless high temperature property measurements by atomic fluorescence

Laser induced fluorescence (LIF) techniques for containerless study of high temperature processes and material properties was studied. Gas jet and electromagnetic levitation and electromagnetic and laser heating techniques are used with LIF in earth-based containerless high temperature experiments. Included are the development of an apparatus and its use in the studies of (1) chemical reactions on Al2O3, molybdenum, tungsten and LaB6 specimens, (2) methods for noncontact specimen temperature measurement, (3) levitation jet properties and (4) radiative lifetime and collisional energy transfer rates for electronically excited atoms.

Schiffman, R. A.↗

DOE OSTI2024

Applications of LIF to Document Natural Variability of Chlorophyll Content and Cu Uptake in Moss

Chlorophyll has long been used as a natural indicator of plant health and photosynthetic efficiency. Laser-induced fluorescence (LIF) is an emerging technique for understanding broad spectrum organic processes and has more recently been used to monitor chlorophyll response in plants. Previous work has focused on developing a LIF technique for imaging moss mats to identify metal contamination with the current focus shifting toward application to moss fronds and aiding sample collection for chemical analysis. Two laser systems (CoCoBi a Nd:YGa pulsed laser system and Chl-SL with two blue continuous semiconductor diodes) were used to collect images of moss fronds exposed to increasing levels of Cu (1, 10, and 100 nmol/cm 2 ) using a CMOS camera. The best methods for the preprocessing of images were conducted before the analysis of fluorescence signatures were compared to a control. The Chl-SL system performed better than the CoCoBi, with dynamic time warping (DTW) proving the most effective for image analysis. Manual thresholding to remove lower decimal code values improved the data distributions and proved whether using one or two fronds in an image was more advantageous. A higher DTW difference from the control correlated to lower chlorophyll a/b ratios and a higher metal content, indicating that LIF, with the aid of image processing, can be an effective technique for identifying Cu contamination shortly after an event.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing↗

DOE OSTI2024

Deep learning based x-ray spectrometer for high repetition rate characterization of betatron radiation

Betatron radiation produced from a laser-wakefield accelerator is a broadband, hard x-ray (>1 keV) source that has been used in a variety of applications in medicine, engineering, and fundamental science. Further development and optimization of stable, high repetition rate (HRR) (>1 Hz) betatron sources will provide a means to extend their application base to include single-shot dynamical measurements of ultrafast processes or dense materials. Recent advances in laser technology used in such experiments have enabled increases in shot-rate and system stability, providing improved statistical analysis and detailed parameter scans. However, unique challenges exist at high repetition rate, where data throughput and source optimization are now limited by diagnostic acquisition rates and analysis. Here, we present the development of a machine-learning algorithm for the real-time analysis of betatron radiation. We report on the fielding of this deep learning algorithm for online source characterization at the Institut National de la Recherche Scientifique's Advanced Laser Light Source. By fine-tuning an algorithm originally trained on a fully synthetic dataset using a subset of experimental data, the algorithm can predict the betatron critical energy with a percent error of 7.2 % with a reconstruction time of 1.5 ms, providing a valuable tool for real-time, multi-objective optimization at HRR.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Demonstration of and future perspective on scaling ultrafast-laser-ablation microstructuring of Li-ion battery electrodes to roll-to-roll production and large-format cells

This work demonstrates integration of an ultrafast laser onto a roll-to-roll machine, the laser structuring of a double-sided, 700 m long roll of graphite battery anode and its subsequent manufacture into 27 Ah prismatic cells. The electrode was ablated with a novel hybrid-microstructure composed of both hexagonally arranged pores for enhanced rate performance and channels for fast electrolyte wetting. Subsequently, this anode and a non-ablated baseline anode are paired with an NMC111 cathode for cell building and electrochemical characterization. Compared to the baseline, laser ablated cells demonstrated a reduction in soaking time of at least 60%, an improvement in fast charge capability with >30% more capacity accepted during 6C charging, and an extension of cycle life of >40% during 0.5C cycling. Further, a perspective is provided on scaling ultrafast laser ablation of battery electrodes to industrial throughputs. Additionally, lessons learned from this pilot-scale demonstration are provided in regards to optical architecture, debris removal, and system control. A techno-economic analysis is used to demonstrate that laser ablation can be integrated into existing electrode manufacturing facilities with only ≈$\$$1.3 per kWh increase (≈2%) in manufacturing cost. Preemptive electrode design for laser ablation is discussed as a further method for enhancing performance. Finally, an analysis of available laser systems and beam-scanning architectures is used to determine design requirements to scale process throughput to a state-of-the-art speed of 50 m min −1 . This analysis demonstrates that laser ablating Li-ion battery electrodes has multiple benefits to manufacturing and battery performance, that the technology already exists to achieve high laser-ablation throughputs, and that integrating ultrafast laser ablation to electrode manufacturing will not create a cost or processing bottleneck.

25 ENERGY STORAGE↗

NASA NTRS2014

Investigation into the Use of the Concept Laser QM System as an In-Situ Research and Evaluation Tool

The NASA Marshall Space Flight Center (MSFC) is using a Concept Laser Fusing (Cusing) M2 powder bed additive manufacturing system for the build of space flight prototypes and hardware. NASA MSFC is collecting and analyzing data from the M2 QM Meltpool and QM Coating systems for builds. This data is intended to aide in understanding of the powder-bed additive manufacturing process, and in the development of a thermal model for the process. The QM systems are marketed by Concept Laser GmbH as in-situ quality management modules. The QM Meltpool system uses both a high-speed near-IR camera and a photodiode to monitor the melt pool generated by the laser. The software determines from the camera images the size of the melt pool. The camera also measures the integrated intensity of the IR radiation, and the photodiode gives an intensity value based on the brightness of the melt pool. The QM coating system uses a high resolution optical camera to image the surface after each layer has been formed. The objective of this investigation was to determine the adequacy of the QM Meltpool system as a research instrument for in-situ measurement of melt pool size and temperature and its applicability to NASA's objectives in (1) Developing a process thermal model and (2) Quantifying feedback measurements with the intent of meeting quality requirements or specifications. Note that Concept Laser markets the system only as capable of giving an indication of changes between builds, not as an in-situ research and evaluation tool. A secondary objective of the investigation is to determine the adequacy of the QM Coating system as an in-situ layer-wise geometry and layer quality evaluation tool.

Bagg, Stacey↗

NASA NTRS2004

Improved Position Sensor for Feedback Control of Levitation

An improved optoelectronic apparatus has been developed to provide the position feedback needed for controlling the levitation subsystem of a containerless-processing system. As explained, the advantage of this apparatus over prior optoelectronic apparatuses that have served this purpose stems from the use of an incandescent lamp, instead of a laser, to illuminate the levitated object. In containerless processing, a small object to be processed is levitated (e.g., by use of a microwave, low-frequency electromagnetic, electrostatic, or acoustic field) so that it is not in contact with the wall of the processing chamber or with any other solid object during processing. In the case of electrostatic or low-frequency electromagnetic levitation, real-time measurement of the displacement of the levitated object from its nominal levitation position along the vertical axis (and, in some cases, along one or two horizontal axes) is needed for feedback control of the levitating field.

Hyers, Robert↗

DOE OSTI2020

Noncontact Flow Rate Using Laser Ultrasonics

Several types of advanced nuclear reactors are cooled with high-temperature liquid metal or molten salt flows. There is a critical need to measure flow velocity in flow channels for test purposes, and eventually in operational reactors. In conventional ultrasonic flow sensors, ultrasonic waves traveling in both the upstream and downstream directions are generated and detected by transducers that must contact the flow channels. A shift in the frequency or transit time between the two ultrasonic waves is measured to determine flow velocity. We describe here an initial effort to apply that sensing concept when the contact transducers are replaced by laser-based generation and detection instrumentation. This noncontact sensing avoids many practical problems associated with contact transducers when implemented on flow channels at high temperature. Laser-based flow monitoring can also be applied to hot-process piping in the geothermal energy, chemical-processing and petroleum-refining industries. Our effort has included theoretical simulation of noncontact laser-based flow monitoring, indicating capability of measuring flow velocities relevant to reactor cooling. It also included a room-temperature experimental demonstration using water as the flow liquid, and indicating capability of measuring flow velocity at a responsivity roughly consistent with simulation predictions. Plans were made for an experimental demonstration at Oregon State University using liquid metal at 110 degrees C.

02 PETROLEUM↗

NASA NTRS1984

Transient processes in combustion of single submillimeter metal droplets

A laser was used to ignite Al, Zr, Ti and Hf droplets in separate trials to study metal droplet combustion in air. The burning was recorded with high speed film at high magnification. Al was found to flash vaporize, melt, surface oxidize, revaporize, then combust. All species burned with a vapor diffusion flame surrounded by an oxide condensation front. The Zr, Ti and Hf droplets grew by condensation, coalesced, then convected toward the perimeter of the condensation zone. It is expected that the data will serve as bases for a theoretical vapor diffusion model. Finally, the introduction of a transverse acoustic field was observed to have no effect on either the luminosity or combustion zone geometry.

Pellett, G. L.↗

NASA NTRS1987

Intelligent robotic tracker

An intelligent tracker capable of robotic applications requiring guidance and control of platforms, robotic arms, and end effectors has been developed. This packaged system capable of supervised autonomous robotic functions is partitioned into a multiple processor/parallel processing configuration. The system currently interfaces to cameras but has the capability to also use three-dimensional inputs from scanning laser rangers. The inputs are fed into an image processing and tracking section where the camera inputs are conditioned for the multiple tracker algorithms. An executive section monitors the image processing and tracker outputs and performs all the control and decision processes. The present architecture of the system is presented with discussion of its evolutionary growth for space applications. An autonomous rendezvous demonstration of this system was performed last year. More realistic demonstrations in planning are discussed.

Otaguro, W. S.↗

NASA NTRS1974

Computer simulation of a fringe type laser velocimeter

A computer simulation of a fringe type laser velocimeter has been written to determine the theoretical characteristics of the laser velocimeter when applied to a given flow field. The program includes the effect of particle size and composition on particle lag, light scattering characteristics and signal contrast. The model of the laser velocimeter includes the laser, optical system, photomultiplier, and counter type data processing electronics. The LV particle size analyzer is also modeled and incorporated in the program. An example application of the program to a Mach 5 wind tunnel using a backscatter laser velocimeter is presented.

Meyers, J. F.↗

DOE OSTI2023

Spatio-temporally shaped deep UV laser source for ultrabright photocathodes using novel upconversion techniques (Final Report)

The goal of this project was to take a VUV laser system designed by Kapteyn-Murnane Labs (KMLabs)—the Hyperion VUV, and increase its functionality, efficiency, and applicability by further probing the fundamental physics taking place in the system and optimizing the system performance. More specifically, DOE accelerator applications—particularly for XFELs that require low-emittance electron beams, require precisely controlled ultrashort pulses in the deep-UV at 250-260 nm to drive the photocathode electron source. This is conventionally done using an ultrafast infrared laser, with subsequent stages of nonlinear upconversion in solid-state nonlinear-optical crystal media (principally BBO, which is commonly used for UV upconversion). However, maintaining high spatial mode beam quality, as well as precisely controlled temporal profile, has proven a persistent challenge. As a possible alternative to this approach, KMLabs has demonstrated a system that generates vacuum ultraviolet light (VUV) by upconverting pulses from an infrared ultrafast laser in a gas-filled hollow waveguide, driving a process of highly cascaded harmonic generation (HCHG). Because HCHG upconversion is done in a gas, rather than a solid, at high intensity in a guided-wave geometry, it retains an excellent beam spatial profile as well as a large spectral bandwidth that allows for control over the temperal structure of the pulse. A challenge, however, is in energy scaling of this HCHG technique to the ~1-20 μJ pulses required for photocathode applications. To-date, the pulse energies used in published HCHG work are sub-10-nJ. This project proposed to explore ways to generate higher-energy pulses using HCHG, as well as to investigate spectral and temporal shaping of the deep UV pulses by pulse shaping the infrared laser used to seed the process. Although we showed that our approach works for generating light at 259 nm, the total pulse energy achieved seems limited to approximately the same value as past work. However, the techniques we investigated may well have benefits for extending this source to much shorter wavelength output.

43 PARTICLE ACCELERATORS↗

NASA NTRS1986

NDE reliability and process control for structural ceramics

The reliability of microfocus x-radiography and scanning laser acoustic microscopy for detecting microvoids in silicon nitride and silicon carbide was statistically evaluated. Materials- and process-related parameters that influenced the statistical findings in research samples are discussed. The use of conventional x-radiography in controlling and optimizing the processing and sintering of an Si3N4-Si02-Y203 composition designated NASA 6Y is described. Radiographic evaluation and guidance helped develop uniform high-density Si3N4 modulus-of-rupture bars with improved four-point flexural strength (857, 544, and 462 MPa at room temperature, 1200 C, and 1370 C, respectively) and reduced strength scatter.

Baaklini, G. Y.↗

NASA NTRS1987

NDE reliability and process control for structural ceramics

The reliability of microfocus X-radiography and scanning laser acoustic microscopy for detecting microvoids in silicon nitride and silicon carbide was statistically evaluated. Materials- and process-related parameters that influenced the statistical findings in research samples are discussed. The use of conventional X-radiography in controlling and optimizing the processing and sintering of an Si3N4-SiO2-Y2O3 composition designated NASA 6Y is described. Radiographic evaluation and guidance helped develop uniform high-density Si3N4 modulus-of-rupture bars with improved four-point flexural strength (857, 544, and 462 MPa at room temperature, 1200 C, and 1370 C, respectively) and reduced strength scatter.

Baaklini, G. Y.↗