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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

3D Printing with Mixed Powders of Boron Carbide and Al Alloy

Laser additive manufacturing with mixed powders of boron carbide and aluminum alloy is investigated. Parameters such as laser power, scan speed, scan pattern, and hatching space are systematically evaluated and optimized to obtain the desired density and porosity. These results show that the AM part contains 20 wt% boron carbide and 80 wt% aluminum alloy, which are well mixed and synthesized during the melting process. Its mechanical properties are close to those of aluminum. A thin-wall structure based two dimensional and three dimensional radial collimators were fabricated with well-controlled geometry for neutron scattering measurement.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Support of Adhesion Mechanisms in Al 2 O 3 Aerosol Deposition Through Laser-Induced Particle Impact Testing

Aerosol deposition (AD) is a kinetic spray process capable of depositing ceramic coatings at room temperature, but AD process development is generally a laborious exploration of a large process parameter space. Here, this paper presents a case study investigating whether laser-induced particle impact testing (LIPIT) could be applied to expedite development of an alumina (Al 2 O 3 ) coating on nickel (Ni): Specifically, whether LIPIT measurements could predict critical velocities of adhesion on Ni and Al 2 O 3 , and the effect of ball milling the Al 2 O 3 powder. Because LIPIT has a diffraction-limited lower bound on imageable particle size, the usefulness of Al 2 O 3 powder agglomerates as a proxy for single particles was additionally studied. Overall, LIPIT measurements and AD sprays agreed that ball milling dramatically improves adhesion. Additionally, LIPIT measurements of critical velocity of adhesion of Al 2 O 3 powder agglomerates on Ni and Al 2 O 3 substrates (150 meters per second [m/s] and 250 m/s, respectively) quantitatively agreed with predictions from a previously published model based on picoindentation and molecular dynamics simulations. Together, these findings support the established hypothesis that Al 2 O 3 adheres via a dislocation-mediated mechanism in AD, that Al 2 O 3 powder agglomerates adhere as individual constituent particles rather than collectively, and that, for this case study, LIPIT measurements were predictive of AD process parameters.

Al2O3↗
DOE OSTI2024

Formation of collisionless shocks driven by strongly magnetized relativistic electrons in the laboratory

In experiments performed with the OMEGA EP laser system, proton deflectometry captured magnetic field dynamics consistent with collisionless shock formation driven by strongly magnetized relativistic electrons. During laser-foil interactions, shocks can form as relativistic electrons and strong surface magnetic fields generated by a short-pulse laser impinge on a cooler plasma produced by a longer-pulse laser. Three-dimensional particle-in-cell simulations reproduce the magnetic draping and fast formation speeds measured in the experiment and reveal that this relativistic-electron-driven shock forms at an interface that is unstable to shear and streaming instabilities. The simulation results provide insight into the microphysics that may influence high-energy shocks observed in extreme astrophysical environments. Published by the American Physical Society 2024

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Generation and Control of Self-Organized Nonlinear Kinetic Structures in High Energy Density Plasmas in the Presence of Intense Magnetic Fields and Ultrashort Laser Pulses

In the project we investigated mechanisms to sculpt phase space by controlling plasma instabilities. We found that linear theory, which applies in the initial growth phase of an instability, allows for initial conditions that can suppress instabilities. This provides a possible mechanism to release the energy available to an instability on demand. We developed various computational techniques that can reduce computational cost of simulations while maintaining or improving physical fidelity. We considered the Buneman instability in the presence of a ponderomotively driven plasma wave to examine the interplay between an instability and steady-state plasma response.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

A dimensionless number for high-throughput design of multi-principal element alloys in directed energy deposition

The present study demonstrates the development of a dimensionless number to predict the build height in the additive manufacturing technique of directed energy deposition (DED). The build height can also be used to estimate the dendrite arm spacing and, thus, the cooling rate in the fabrication of samples. A baseline sample, 316L stainless steel, was used to fit the build height to the dimensionless number. A range of process parameters, including laser power, laser feed rate, powder flow rate, layer thickness, and hatch spacing, were varied. Based upon dendrite arm spacing, the estimated cooling rate varied between 102 and 104 K/s. Using the fitted relationship for the stainless steel, high-throughput (HT) processing of multi-principal element alloys (MPEAs) was performed. For this study, HT is the ability to fabricate a batch of 25 bulk samples (∼1 cm3) with different compositions within a 5-h period with ±10 at. % accuracy. A range of compositions using in situ alloying of elemental powders in the Fe–Ni–Cr–Mo system were made. The MPEAs' build height followed the same relationship to the dimensionless number as the 316L alloy. The dimensionless number predicts both macro and meso-scale features in HT processing, thus offering a design tool for choosing process parameters in DED additive manufacturing. Also, the ability to control or increase cooling rates can enhance the ability to promote metastability as well as control meso-scale chemical distributions of alloy samples.

Islam, Zahabul (ORCID:0000000169613209)↗
DOE OSTI2022

A process optimization framework for laser direct energy deposition: Densification, microstructure, and mechanical properties of an Fe-Cr alloy

Laser Direct Energy Deposition (DED) is a metal additive manufacturing technique with the ability to fabricate large and complex parts through deposition of metal powders. However, achieving high-density parts and targeted build heights using DED can be challenging due to the large number of highly sensitive process variables. This work proposes a robust fabrication parameter optimization framework to generate process maps for primary parameters in DED, including laser power, scan speed, mass flow rate, hatch spacing, and layer height. Simple single-track experiments were utilized to map out the parameter space, and a combination of geometric criteria for hatch spacing and layer height were proposed to determine parameter sets that achieve both targeted build heights and mitigate porosity formation. Using this framework, specimens with >99 % density and consistent mechanical properties were successfully fabricated over a wide range of process parameters for an Fe-9wt.%Cr (Fe9Cr) alloy, a surrogate for radiation damage-resistant reduced activation ferritic/martensitic (RAFM) steels. Processing these materials using DED is of particular interest in the development of plasma facing components for nuclear fusion applications. The microstructure and mechanical properties of as-printed Fe9Cr were characterized using optical and electron microscopy, X-ray diffraction, and uniaxial tensile tests. As-printed Fe9Cr displayed ~25 % elongation and ultimate tensile strengths of up to 475 MPa which is comparable to similar wrought alloys. Finally, the proposed framework will allow for accelerated DED parameter optimization for novel alloy systems, as well as open the possibility for local microstructure control while simultaneously mitigating defect formation.

42 ENGINEERING↗
DOE OSTI2026

Entropy-mode-driven gas optics

We propose a class of gaseous diffractive optical elements created by imprinting an entropy mode in a gas. Previous approaches to gaseous diffractive optics have relied on the simultaneous excitation of a standing acoustic wave and an entropy mode to produce one-dimensional periodic structures. However, the presence of acoustic oscillations in the gas imposes stringent constraints on some of the operational parameters of these optical elements, such as their lifetime and diffraction angle. Here, in this work, we introduce an approach that eliminates the acoustic mode, relying solely on the entropy mode. This enables control of the lifetime and temporal profile of gaseous optical elements, and also allows the creation of arbitrary structures with greater contrast, including nonperiodic patterns such as chirped gratings or lenses. This approach should allow operation over a wider parameter space, including larger diffraction angles and compatibility with laser pulse durations ranging from femtoseconds to microseconds.

Optics and optical instruments↗
DOE OSTI2022

Nondestructive Evaluation of Stress Corrosion Cracking in a Welded Steel Plate Using Guided Ultrasonic Waves

Stress corrosion cracking (SCC) had occurred in early-generation high-level nuclear waste tanks constructed by welding carbon steel. This paper describes an ultrasonic inspection system and its fundamental ability to detect and quantify the length of SCC on thick welded steel plates. The finite element method (FEM) was applied to simulate the welding process to estimate the welding residual stress field. Growth of stress corrosion cracks is driven by crack stress intensities exceeding the subcritical cracking threshold intensity. The subject plate was experimentally inspected with ultrasonic nondestructive evaluation (NDE) techniques to characterize the extent of SCC. The NDE system uses a piezoelectric transducer to generate guided waves in the thick steel plate, and a scanning laser Doppler vibrometer (SLDV) to measure multidimensional time–space wavefield data over a user-defined scanning area in the plate surface. The measured wavefield data can show wave interactions in a localized area in the plate due to the presence of the discontinuities of the SCC. To generate an inspection image that can precisely show the crack’s location and/or the dimension, the wavefield data are further processed to generate inspection image that maps the entire sample plate so the crack can be clearly identified in the plate while its length can be readily estimated. In conclusion, the ultrasonic test results for crack length agree well with the visually estimated length and are close to that predicted by the FEM for cracks in the weld residual stress field.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Lawrence Livermore National Laboratory – Innovation and Partnerships Office (IPO): FY24 Technology Transfer Report (2025 Report V3)

Lawrence Livermore National Laboratory’s (LLNL) Innovation and Partnerships Office (IPO) is the focal point for Laboratory engagement with industry. Organizations partner with LLNL to unlock the commercial viability of breakthrough technologies invented at the Laboratory and collaborate to mature them in order to solve complex industry challenges. LLNL technology transfer connects cutting-edge science with real-world applications, empowering businesses to thrive while advancing the nation’s technological edge. We do this by identifying new economic opportunities, protecting LLNL intellectual property (IP) and transferring it to the private sector through licensing and partnerships

42 ENGINEERING↗
DOE OSTI2024

Empirical Investigation of Properties for Additive Manufactured Aluminum Metal Matrix Composites

Laser additive manufacturing with mixed powders of aluminum alloy and silicon carbide (SiC) or boron carbide (B4C) is investigated in this experiment. With various mixing ratios of SiC/Al to form metal matrix composites (MMC), their mechanical and physical properties are empirically investigated. Parameters such as laser power, scan speed, scan pattern, and hatching space are optimized to obtain the highest density for each mixing ratio of SiC/Al. The mechanical and thermal properties are systematically investigated and compared with and without heat treatment. It shows that 2 wt% of SiC obtained the highest strength and Young’s modulus. Graded composite additive manufacturing (AM) of MMC is also fabricated and characterized. Various types of MMC devices, such as heat sink using graded SiC MMC and grid type three-dimensional (3D) neutron collimators using boron carbide (B4C), were also fabricated to demonstrate their feasibility for applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Performance of laser ion source LION operated at Brookhaven National Laboratory

LION is a laser ion source that has been in operation at Brookhaven National Laboratory (BNL) to provide heavy ions for NASA Space Radiation Laboratory (NSRL) and Relativistic Heavy Ion Collider (RHIC). It is the first laser ion source to supply stable ion beams for a long-term operation for users at a large accelerator facility in the world. LION is located at the upstream end of the heavy ion accelerator complex at BNL and supplies singly charged ion beams of various ion species. LION has been in operation since 2014 and is planned to be upgraded in 2024. This paper summarizes the operational performance achieved by LION.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Compact laser source with frequency modulators generating multiple lines

A compact laser source and a single sideband modulator used therein is disclosed. The compact laser source includes a seed laser and one or more channels, with each channel generating one or more output laser beams having corresponding different wavelengths. The compact laser source can be formed in whole or in part on a single optical motherboard to thereby minimize space and power requirements. By employing the disclosed single sideband modulator, harmonics in the generated output laser beams can be minimized. The compact laser source finds application in an atom interferometer (AI) system, which may be used to measure gravity, acceleration, or rotation of the AI system.

Lentine, Anthony L.↗
DOE OSTI2021

Two-dimensional retrieval methods for ultrafast imaging of molecular structure using laser-induced electron diffraction

Molecular structural retrieval based on electron diffraction has been proposed to determine the atomic positions of molecules with sub-angstrom spatial and femtosecond temporal resolutions. Given its success on small molecular systems, in this work, we point out that the accuracy of structure retrieval is constrained by the availability of a wide range of experimental data in the momentum space in all molecular systems. To mitigate the limitations, for laser-induced electron diffraction, here we retrieve molecular structures using two-dimensional (energy and angle) electron momentum spectra in the laboratory frame for a number of small molecular systems, which have previously been studied with 1D methods. Compared to the conventional single-energy or single-angle analysis, our 2D methods effectively expand the momentum range of the measured data. Besides utilization of the 2D data, two complementary methods are developed for consistency check on the retrieved results. Further, the 2D nature of our methods also offers a way of estimating the error from retrieval, which has never been explored before. Comparing with results from prior experiments, our findings show evidence that our 2D methods outperform the conventional 1D methods. Paving the way to the retrieval of large molecular systems, in which their tunneling ionization rates are challenging to obtain, we estimate the error of using the isotropic model in place of including the orientation-dependent ionization rate.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2026

Experimental longitudinal emittance manipulation using laser-based photoionization in the Fermilab Linac

A series of simulations and beam studies were conducted at Fermilab’s linear accelerator to evaluate the effectiveness of longitudinal emittance control via laser-induced photoionization. While similar laser techniques have been employed at Fermilab to enhance injection and extraction efficiency into the Booster, the work presented here focuses on extending these methods to bunch-by-bunch manipulation. This approach utilizes fine-scale correction of the H- bunches’ longitudinal spatial distribution. In theory, loosely confined particles in longitudinal phase space contribute to emittance growth during acceleration. By selectively removing these outlying particles through laser scraping (H- + γ → H + e-), this growth can be reduced. This report presents experimental results from both symmetric and asymmetric longitudinal scraping of H⁻ bunches in the Fermilab linac, which were subsequently injected into Booster, and evaluates the broader applicability of this method for future high-intensity accelerator operations.

Landon, Parker [Boston U.; Fermilab]↗
DOE OSTI2026

Collisionless Larmor coupling and blob formation in a laser-plasma expanding into a magnetized ambient plasma

Collisionless Larmor coupling is a fundamental process in space and astrophysical plasmas that enables momentum transfer between an expanding plasma and a magnetized ambient medium. Here, in this paper, we report on the laboratory experimental study of Larmor coupling leading to the formation of a plasma blob associated with a laser-driven, super-Alfvénic plasma flow on the Large Plasma Device at the University of California, Los Angeles. The high-repetition rate enables systematic spatial and temporal scans of the plasma evolution using Doppler spectroscopy, as well as measurements of the magnetic field, electrostatic field, and self-emission of both debris and ambient ions using filtered imaging. We observe the self-focusing of the laser-produced plasma and the formation of a secondary diamagnetic cavity associated with a blob composed of background ions. Doppler spectroscopy reveals the transverse velocity distribution of the background ions, providing direct evidence of ion energization via Larmor coupling. The systematic spatial and temporal scans enabled by the high-repetition-rate experiment allow for a detailed characterization of the ion dynamics. These experimental observations are supported by numerical simulations that provide more insight into the kinetic-scale physics associated with blob formation as well as the role of the ambient plasma density.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Demonstration of Control of Laser-Plasma Instabilities in the Laboratory Using STUD Pulses (Spike Trains of Uneven Duration and Delay)

The success of laser Driven Inertial Fusion Technology (LaDrIFT) hinges on controlling laser-plasma instabilities (LPI) for effective and non-deleterious energy coupling, together with the control of implosion hydrodynamic instabilities (IHI) for target integrity. Conventional approaches ignore LPI and focus on IHI. LPI control suggests the use of low intensities, short wavelengths, and thus the slow implosions of thinner shells, while IHI control calls for thicker shells, fast implosions and thus at higher laser intensities and ablation pressures. These contradicting requirements severely restrict LaDrIFT design space, flexibility and scalability. This program demonstrates, with theoretical designs and their preliminary experimental realizations, that STUD pulses (Spike Trains of Uneven Duration and Delay) can control LPI in high-energy-density (HED) laser-created plasmas and explore this physics for the first time with high repetition (rep) rate lasers.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Ultra-fast transverse beam orbit control in LCLS copper linac. Part I

We report current and future experiments at LCLS require x-ray pulse trains of variable time separation on the nanosecond scale. For instance, the cavity-based XFEL (CBXFEL) will use up to 4 pulses separated by 218.5 ns, the X-ray Laser Oscillator (XLO) will use 15 to 25 ns spaced pulses, and the Matter under Extreme Conditions (MEC) experiments use pulse trains separated by 5 nanoseconds or less. In this paper, we demonstrate an ultra-fast e-beam trajectory control method based on transverse electro-magnetic (TEM) striplines and state-of-the-art power sources, to enhance LCLS operations in these regimes.

47 OTHER INSTRUMENTATION↗