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At least 1,423 records · Page 79

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DOE OSTI2024

ThermoPore: Predicting part porosity based on thermal images using deep learning

Part qualification is often a critical and labor-intensive process in additive manufacturing, particularly in the detection of defects such as porosity, which stands to benefit significantly from advancements in machine learning. We present a deep learning approach for quantifying and localizing ex-situ porosity within Laser Powder Bed Fusion fabricated samples utilizing in-situ thermal image monitoring data. Our goal is to build the real time porosity map of parts based on thermal images acquired during the build. The quantification task builds upon the established Convolutional Neural Network model architecture to predict pore count and the localization task leverages the spatial and temporal attention mechanisms of the novel Video Vision Transformer model to indicate areas of expected porosity. Our model for porosity quantification achieved a R 2 score of 0.57 and our model for porosity localization produced an average Intersection over Union (IoU) score of 0.32 and a maximum of 1.0. This work is setting the foundations of part porosity “Digital Twins” based on additive manufacturing monitoring data and can be applied downstream to reduce time-intensive post-inspection and testing activities during part qualification and certification. In addition, we seek to accelerate the acquisition of crucial insights normally only available through ex-situ part evaluation by means of machine learning analysis of in-situ process monitoring data.

Deep learning↗

DOE OSTI2023

In-Situ Observation of the Formation of Laser-Induced Periodic Surface Structures with Extreme Spatial and Temporal Resolution

Irradiation of solid surfaces with intense ultrashort laser pulses represents a unique way of depositing energy into materials. It allows to realize states of extreme electronic excitation and/or very high temperature and pressure and to drive materials close to and beyond fundamental stability limits. As a consequence, structural changes and phase transitions often occur along unusual pathways and under strongly nonequilibrium conditions. Furthermore, due to the inherent multiscale nature—both temporally and spatially—of these irreversible processes, their direct experimental observation requires techniques that combine high temporal resolution with the appropriate spatial resolution and the capability to obtain good quality data on a single pulse/event basis. In this respect, fourth-generation light sources, namely, short wavelength and short pulse free electron lasers (FELs), are offering new and fascinating possibilities. As an example, this chapter will discuss the results of scattering experiments carried out at the FLASH free electron laser at DESY (Hamburg, Germany), which allowed us to resolve laser-induced structure formation at surfaces on the nanometer to submicron length scale and in temporal regimes ranging from picoseconds to several nanoseconds with sub-picosecond resolution.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

Towards synthetic L 1 0 -FeNi: Detecting the absence of cubic symmetry in Laser-Ablated Fe-Ni nanoparticles

The L 1 0 crystal structure underlines an important class of chemically ordered alloys that exhibits uniaxial magnetocrystalline anisotropy. The near-equiatomic L 1 0 -FeNi extracted from meteorites has demonstrated intriguing magnetic properties for permanent magnet applications. However, the synthesis of this chemically ordered non-cubic structure has been a longstanding challenge. Here, in this work, we demonstrate the absence of cubic symmetry in near-equiatomic Fe-Ni nanoparticles synthesized by picosecond-pulsed laser ablation in liquids. The non-cubic phase detected in these particles can only be L 1 0 -FeNi or hexagonal close-packed (HCP) FeNi, and the absence of cubic symmetry was unequivocal. The orientation relationship between the non-cubic phase and the adjacent cubic phase was characterized by a series of transmission electron microscopy (TEM) techniques, which consistently suggests that the formation of the non-cubic phase involves a martensitic transformation process.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Structural mechanism of Escherichia coli cyanase

Cyanase plays a vital role in the detoxification of cyanate and supplies a continuous nitrogen source for soil microbes by converting cyanate to ammonia and carbon dioxide in a bicarbonate-dependent reaction. The structures of cyanase complexed with dianion inhibitors, in conjunction with biochemical studies, suggest putative binding sites for substrates. However, the substrate-recognition and reaction mechanisms of cyanase remain unclear. Here, crystal structures of cyanase from Escherichia coli were determined in the native form and in complexes with cyanate, bicarbonate and intermediates at 1.5–1.9 Å resolution using synchrotron X-rays and an X-ray free-electron laser. Cyanate and bicarbonate interact with the highly conserved Arg96, Ser122 and Ala123 in the active site. Further, in the presence of a mixture of cyanate and bicarbonate, three different electron densities for intermediates were observed in the cyanase structures. Moreover, the observed electron density could explain the dynamics of the substrate or product. In addition to conformational changes in the substrate-binding pocket, dynamic movement of Leu151 was observed, which functions as a gate for the passage of substrates or products. These findings provide a structural mechanism for the substrate-binding and reaction process of cyanase.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Characterizing the acceleration time of laser-driven ion acceleration with data-informed neural networks

Peak ion energy is an important figure-of-merit in short-pulse, laser-driven ion acceleration and is dependent on an associated acceleration time. Standard metrics for these quantities depend on analytical results such as the self-similar fluid model or empirical models based on relatively small experimental and simulation datasets. In this work we attempt to use a data-informed neural network (NN) as a surrogate model for a large ensemble of PIC simulations to investigate an effective acceleration time. We explore the application of a stacked convolutional and recurrent NN architecture for improved regression by incorporating the time dependencies of the data into the training process. Of particular note is how pretraining a network on lower fidelity data, e.g. 1D analytical results, greatly improves the network's ability to learn more complex, higher fidelity data. Finally, the dependency of the acceleration time on various laser and plasma parameters is explored.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

New perspectives on materials and device dynamics using time-resolved full-field diffraction X-ray imaging

Understanding how materials evolve during synthesis, processing, or device operation requires experimental access to structural dynamics across wide ranges of length and time scales, often in bulk samples or even within packaged devices. Time-resolved full-field diffraction X-ray microscopy has recently emerged as a powerful way to meet this need by combining the penetration and structural sensitivity of X-ray diffraction with objective-lens-based magnification, sensitive high-resolution X-ray imaging detectors, and pump-probe and real-time imaging strategies. Advances in full-field X-ray diffraction microscopy, often termed dark-field X-ray microscopy (DFXM), enable simultaneous imaging of extended fields of view while retaining crystallographic selectivity. Time-resolved DFXM promises to enable advances in materials processing and dynamics, electrochemical and photochemical processes, and the design of electronic devices. This Perspective summarizes the key instrumental concepts that define the performance of these methods, including the choice of imaging optics, detector considerations, and the impact of source time structure at synchrotron light sources and X-ray free-electron lasers (XFELs). We discuss the simultaneous use of complementary imaging modes that are increasingly used in practice. The early demonstrations of the potential of time-resolved DFXM include real-time defect and grain-boundary dynamics during metal annealing, stroboscopic imaging of functional devices with high strain sensitivity, and ultrafast pump-probe implementations at XFELs that directly visualize acoustic-wave propagation and energy dissipation in bulk crystals.

Dark-field X-ray microscopy↗

DOE OSTI2020

A generalized forward fit for neutron detectors with energy-dependent response functions

To date, most analysis of neutron time-of-flight data from inertial confinement fusion experiments has focused on the relatively small range of energies corresponding to the primary neutrons from DD and DT fusion, and have therefore employed instrument response functions (IRF’s) corresponding to monoenergetic 2.45-MeV or 14.03-MeV neutrons. For analysis of time-of-flight signals corresponding to broader ranges of neutron energies, accurate treatment of the data requires the use of an energy-dependent IRF. Here, this work describes interpolation of the IRF for neutrons of arbitrary energy, construction of an energy-dependent IRF, and application of this IRF in a forward fit via matrix multiplication. As an example of the application of this method, an analysis of synthetic data relevant to TT fusion experiments at the Omega Laser Facility is discussed. This example is used to illustrate the differences between a forward fit that uses an energy-dependent IRF and a forward fit that uses a monoenergetic IRF. Use of the energy-dependent IRF is shown to result in accurate inference of the fit parameters of interest.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

The effects of multispecies Hohlraum walls on stimulated Brillouin scattering, Hohlraum dynamics, and beam propagation

We report experiments and simulations have been conducted to investigate the efficacy of Ta 2 O 5 -lined Hohlraum walls at reducing stimulated Brillouin backscattering (SBS) as well as any subsequent effects on the Hohlraum dynamics and capsule implosions in indirect drive experiments at the National Ignition Facility. Using a 1.1 MJ 400 TW, 351 nm, shaped laser pulse, we measure a 5× reduction in SBS power in the peak of the pulse from the wall on the outer 50° cone beams. The SBS spectrum indicates a reduction in the high-Z spectral signature when using multispecies wall materials. Detailed hydrodynamic simulations were performed using different heat conduction models with flux limiters. Additional simulations were performed on the plasma maps using the 3D parallel paraxial code pF3D to compare backscatter powers between the pure Au and Ta 2 O 5 -lined Hohlraums. Further analysis, using hydrodynamically equivalent plasmas, shows that the SBS reduction is clearly a result of the added ion Landau damping caused by the oxygen ions and not from differences in plasma conditions. The experimental and simulation results also show an increase in the wall plasma expansion when using the Ta 2 O 5 liner leading to a 70% more oblate implosion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Low damping (111) oriented lithium aluminum ferrite thin films for spin wave applications

Spin wave-based spintronics are an alternative to conventional electronics due to their potential for efficient energy consumption, improved processing speed, and smaller device dimensions. Low damping magnetic insulators provide the medium for efficient propagation of spin waves for information transfer. Here, we have synthesized by pulsed laser deposition epitaxial spinel structure ferrite thin films of Li 0.5 (Al 1.0 Fe 1.5 )O 4 (LAFO) on (111)-oriented MgAl 2 O 4 that support isotropic magnon propagation in the film plane. Our ferromagnetic resonance measurements show low magnetic damping with a typical Gilbert damping parameter of α = 0.006 and weak-spin–orbit coupling with g = 2.02. These films have low effective magnetization, μ o M eff = 20 mT, similar to that of yttrium iron garnet, the gold standard of low loss magnetic insulators. Our findings show that LAFO is a good candidate as a spin wave medium since it can be grown at low temperatures in different crystal orientations.

Takana, Lerato [Stanford Univ., CA (United States)↗

DOE OSTI2021

Imaging conical intersection dynamics during azobenzene photoisomerization by ultrafast X-ray diffraction

Significance Vibronic coherences are unique features that emerge in the decisive moments of photochemistry and photophysics. Here we demonstrate how X-ray diffraction can access fundamental information about these coherences. This is enabled by recent developments at free-electron lasers, working toward temporal resolution and single-molecule accessibility of scattering-based measurements. Time-resolved diffraction patterns of the isomerization of azobenzene are simulated. The process is monitored in time via the momentum-space signal, with a special focus on the mixed elastic/inelastic scattering from coherences. We give practical ideas on how this relatively weak contribution to the signal can potentially be retrieved. A direct connection to the real-space movie of the conical intersection dynamics is made, enabling the observation of quantum coherences that direct chemical processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Liquid-to-gas transfer of sodium in a liquid cathode glow discharge

Abstract Plasma-liquid interactions have been extensively studied with a focus on the transport of reactive species from the plasma to the liquid phase and their induced liquid phase chemistry and resulting applications. While solute transfer from the liquid to the gas phase in plasmas has been widely used in analytical chemistry, the underlying processes remain relatively unexplored. We report spatially and temporally resolved absolute density measurements of sodium in a plasma with a NaCl solution cathode using two-photon absorption laser induced fluorescence (TaLIF). The observed non-linear increase in sodium density with solution conductivity is shown to correlate with droplet generation as visualized by Mie scattering. The findings are explained by droplet generation by electrospray induced by Taylor cone formation as underpinning mechanism for the introduction of sodium in the plasma. An analytical sheath model combined with a scaling law shows an increase in electric field force with solution conductivity that is consistent with the observed non-linear increase in sodium density in the plasma with solution conductivity.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Ultrafast dynamics of a fermion chain in a terahertz field-driven optical cavity

In this article, we study the effect of a terahertz field-driven single cavity mode for ultrafast control of a fermion chain with dissipation-induced nonlinearity and quadratic coupling to an infrared-active phonon mode. Unlike the first-order phase transition in the nonequilibrium steady state of the system without a cavity or with a high-quality cavity, we find that a realistic dissipation in a low-quality driven cavity process prevents such a transition. Without realistic photon loss from the cavity, the transition only survives for the lower phonon-polariton branch with strong drive; a weak laser field fails to induce the phase transition and renders the polaritons symmetrical. The ability to control the phase transition is crucial for realizing strongly modulated steady states; we propose experimentally feasible regimes where this occurs.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

Laser Powder Bed Fusion Microstructure Surrogate Model

SAND2025-11467O The Laser Powder Bed Fusion (LPBF) Microstructure Surrogate Model is a machine-learning-based tool. It predicts statistics of microstructures that are produced by the LPBF additive manufacturing process. It includes a series of codes for training, testing, and analyzing the model as well as utility scripts for handling data. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Moser, Daniel [Sandia National Lab. (SNL-CA), Live↗

DOE OSTI2020

Stability of zirconium hydride

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

36 MATERIALS SCIENCE↗

DOE OSTI2022

Accelerated Scaling to Rapid Open-Air Fabrication of Durable Perovskite Solar Modules

The goals of this SETO project (DE-EE0008559, Accelerated Scaling to Rapid Open-Air Fabrication of Durable Perovskite Solar modules) are to address the principal challenges towards the successful commercialization of perovskite solar modules utilizing scalable, high-throughput open-air spray deposition. The successful outcome of the project will provide the foundation of an all open-air spray deposited perovskite solar module with hole transport layer (HTL), perovskite, electron transport layer (ETL), and barrier layer development while establishing a fundamental understanding of perovskite device behavior under accelerated aging conditions. Through this program, we have made significant progress towards a commercializable pathway for perovskites. (1) We’ve demonstrated the successful open-air deposition of perovskite and transport layer materials. These deposition methods were chosen for their inherent scalability, and open-air processing enables a significant reduction in processing costs. These methods are also compatible with high throughputs, demonstrating the fastest perovskite film deposition at these performance levels. (2) Development of a unique all-fiber laser scribing procedure provides a high-performance, low-cost method for further improvements in scalability. (3) Our group has also placed a unique emphasis on device stability. The development of testing standards for perovskite modules is required to thoroughly evaluate potential candidates for commercialization, and we’ve taken inspiration from current industry standards to provide an honest insight into the performance and reliability of our devices. (4) An extensive cost model detailing the specific contributions of each device layer and production component provides the most thorough evaluation of any perovskite technology against conventional silicon and compound semiconductor solar devices. The cost model is a critical advancement that will provide the foundation for evaluating the levelized cost of energy (LCOE) of this technology.

14 SOLAR ENERGY↗

DOE OSTI2026

SULI Report - Development of a Molten Salt Circulation Loop for in-situ Spectroscopy

This project supports the development of real time optical monitoring capabilities for molten salt reactor (MSR) environments by designing, testing, and refining a molten salt circulation loop suitable for combined laser induced breakdown spectroscopy (LIBS) and ultraviolet visible (UV Vis) absorption measurements. Online spectroscopic monitoring is increasingly important for nuclear safeguards, corrosion tracking, and material accountancy, yet MSR process fluids present substantial challenges due to their chemical complexity and hazards such as high temperatures and radiation. To address these needs, this work focuses on Phase I, the development of a room temperature aqueous circulation loop that serves as a surrogate platform for evaluating flow behavior, optical access, and component performance prior to high temperature salt operation. Initial testing identified several practical issues—including leaks, obstructions, and two-phase flow through the absorption cell—that were systematically resolved through hardware replacement, flow path redesign, and venturi pressure optimization. Relocating the flow cell upstream of the primary venturi enabled periods of stable single-phase flow, demonstrating the feasibility of integrating optical diagnostics into a circulation system. The results of Phase I provide essential design insight for Phase II, which will incorporate furnace compatible materials and LiCl KCl eutectic salt. Completion of the molten salt system will deliver a reusable testbed for evaluating multimodal spectroscopic techniques, advancing nondestructive, real time monitoring tools for future MSR and nuclear fuel cycle applications.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗

DOE OSTI2020

Three-Dimensional Imaging Lidar for Characterizing Particle Fields and Organisms in the Mesopelagic Zone

The ocean’s mesopelagic zone is largely uncharacterized despite its vital role in sustaining ocean ecosystems. The composition, cycling, and fate of particle fields in the mesopelagic lacks an integrative multi-scale understanding of organism migration patterns, distribution, and diversity. This problem is addressed by combining complementary technologies with overlapping size spectra, including profiler mounted optical scattering sensors, profiler, and ship mounted acoustic devices, and a custom Unobtrusive Multi-Static Lidar Imager (UMSLI). This unique sensor suite can observe distributions of particles including organisms over a six order of magnitude dynamic size range, from microns to meters. Overlapping size ranges between different methods allows for cross-validation. This work focuses on the lidar imaging measurements and optical backscattering and attenuation, covering a combined particle size range of 0.1 mm to several cm. Particles at the small end of this range are sized using an existing backscattering time series inversion method after Briggs et al. (2013). Larger particles are resolved with UMSLI over an expanding volume using three-dimensional photo-realistic laser serial imaging. UMSLI’s image rectifying ability over time allows for derivation of particle concentration, size, and spatial distribution. Technical details on the development and post-processing methods for the novel UMSLI system are provided. Image resolved particle size distributions (PSDs) revealed a size shift from smaller to larger particles (>0.5 mm) as indicated by flatter slopes from dawn (slope = 2.6) to dusk (slope = 3.0). PSD trends are supported by an optical backscatter and transmissometer time series inversion analysis. Size shifts in the particle field are largely attributed to aggregation effects. Images support evidence of temporal variation between dusk and dawn stations through statistical analysis of particle concentrations for particle sizes 0.50–5.41 mm. Spatial analysis of the particle field revealed a dominantly uniform distributed marine snow background. The importance and potential of integrated approaches to studying particle and organism dynamics in ocean environments are discussed.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Toolpath considerations for DED: Arc and laser welding

Directed energy deposition (DED) is a form of additive manufacturing that uses localized melted metal, similar to traditional arc welding, to construct an object. In comparison to polymer systems, metal systems can exert additional control over the build process through manipulation of the pool of melted metal, called the “melt pool.” This is especially important to maintain appropriate layer heights and create high quality builds. Additionally, metal systems allow site-specific control of the printed part, which enables advanced construction techniques that would otherwise not be possible. However, both of these types of control require support from the slicing software and, potentially, sensor feedback. This chapter will discuss these control processes and their basic implementation in a slicing program. The processes described here lay the foundation for more advanced solutions, particularly sensor feedback, that will be discussed later.

Borish, Michael↗