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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 OSTI2021

Determining processing behaviour of pure Cu in laser powder bed fusion using direct micro-calorimetry

We report copper is challenging to process by laser powder bed fusion (LPBF) given its high reflectivity at common infrared laser diode wavelengths and high thermal conductivity. Successful deposition of copper in a predictable and repeatable fashion relies on understanding the development of the keyhole melting regime, as well as heating, melting, boiling and vapour formation behaviour when interacting with a laser beam within an LPBF environment. In this study, in situ optical absorptivity measurements are used to clarify the complex physics of the laser material interaction. Absorptivity of laser energy is measured using direct micro-calorimetry and compared to melt pool depth in correlation to processing parameters. The measured absorptivity for a 100 μm layer thickness of powder was found to be approximately four times higher than that of the bare polished discs. It was also shown that high laser power above 500 W and scan speed up to 150 mm/s are appropriate for effective melting of the powder layer, with these parameters overcoming the threshold required to achieve keyhole melting. This is explained by multiple reflections withing the powder particles and the lower thermal conductivity of packed powder in comparison to bare discs. Melt pool formation was found to be highly unstable and an explosive behavior was observed when in the keyhole regime, caused by high fluctuations in absorptivity values. This work demonstrates calorimetry can be used to monitor melting behaviour in a real-time fashion during processing for this challenging to process material, thereby avoiding unnecessary parametric optimisation. In addition, the parametric window for optimum processing revealed here can inform future work.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Spectral sensor error analysis for measuring x-ray radiation drive using the DANTE diagnostic toward inertial confinement fusion experiments

DANTE is a diagnostic used to measure the x-radiation drive produced by heating a high-Z cavity (“hohlraum”) with high-powered laser beams. It records the spectrally and temporally resolved radiation flux at x-ray energies between 50 eV and 20 keV. Each sensor configuration on DANTE is composed of filters, mirrors, and x-ray diodes to define 18 different x-ray channels whose output is voltage as a function of time. The absolute flux is then determined from the photometric calibration of the sensor configuration and a spectral reconstructing algorithm. The reconstruction of the spectra vs time from the measured voltages and known response of each channel has presented challenges. Here we demonstrate a novel approach here for quantifying the error on the determined flux based on the channel sensor configuration and most commonly used reconstruction algorithm. In general, we find that the integrated spectral flux from a hohlraum can robustly be reconstructed (within ~14%) using a traditional unfold approach with as few as ten channels due to the underlying assumption of a largely Planckian spectral intensity distribution.

47 OTHER INSTRUMENTATION↗
NASA NTRS1975

Dynamic sampling of laser-induced vapor plumes by mass spectrometry

Mass spectrometric techniques and instrumentation for the dynamic sampling of laser-induced vapor clouds during their submillisecond expansion periods are discussed. Illustrations are drawn primarily from the results of pulsed-laser heating of some oxides and graphites; these include comparisons of incident laser beam pulses with the resultant pulses of positive ions and selected neutral species. Observed characteristics of vapor pulses from graphite are shown to correlate with calculated surface temperature response. Dynamic velocity measurements of individual vapor species are described and, from these velocities, vaporization temperatures are derived and compared using four gas dynamic models for vapor expansion into vacuum. Additional measurements indicate that the laser beam may interact directly with the neutral vapors to produce ions.

Lincoln, K. A.↗
DOE OSTI2021

Development of a versatile, high-temperature, high-throughput ion irradiation system

We report ion irradiation has long been used as a surrogate for neutron irradiation experiments which are comparatively slower, more expensive, and often can leave materials activated and difficult to handle post-irradiation. However, with the growing use of combinatorial synthesis methods and high-throughput, automated characterization techniques, ion irradiation facilities will need to upgrade their capabilities to be able to accommodate these new material platforms. To address this challenge, a high-throughput ion irradiation system has been developed at the University of Wisconsin-Madison Ion Beam Laboratory (IBL). The system is capable of accommodating large sample arrays of arbitrary geometries and heat samples individually using an infrared laser to enable high-temperature, high-throughput ion irradiation while mitigating the risk of annealing the irradiation damage in nearby samples. To control stage motion, laser power, and beam current measurement, among other tasks, the program Chronos was developed which enables automated high-throughput irradiation experiments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2018

Testing with the Laser-Enhanced Arc Jet Facility (LEAF) at NASA Ames Research Center

NASA's new Laser-Enhanced Arcjet Facility (LEAF) employs 200 kilowatts of continuous-wave fiber lasers, combined with a 60-megawatt arc plasma jet, to simulate the combined radiative and convective heating is now operational and Orion heat-shield material is undergoing testing. This upgrade to the existing Interaction Heating Facility (IHF) involves the addition of high-power fiber lasers that project 1070nm radiative energy into the existing vacuum chamber. The optically expanded laser beam enters a side window of the test chamber to form either a uniform 150 x 150 mm or a 425 x 425 mm square spot on a wedge-shaped model holder. Combined heating levels of up to 180 W/cm2 convective with either 300 W/cm2 or 100 W/cm2 are achievable. This allows the arc jet and lasers to simulate dynamic entry-heating profiles encountered during entry by the Orion crew capsule for the lunar return conditions. New computational investigations are underway to explore testing with the objective of defining ablative material failure limit. Typical arc-jet testing is performed with test article that are stagnation or wedge geometries. The existing convective heating test facility combined with test article design limits how high a combined shear, heat-flux and pressure conditions can be achieved. With the addition of laser power of 200 kW, much higher combined conditions of high heat-flux, pressure and shear is achievable on a wedge or a swept-cylinder article. Such testing possibilities will allow us to progressively increase the combined conditions and explore when an ablative TPS material may fail. The presentation provides an overview of the LEAF and present results from the on-going Orion Testing.

Venkatapathy, Ethiraj↗
NASA NTRS1979

Laser rocket system analysis

The laser rocket systems investigated in this study were for orbital transportation using space-based, ground-based and airborne laser transmitters. The propulsion unit of these systems utilizes a continuous wave (CW) laser beam focused into a thrust chamber which initiates a plasma in the hydrogen propellant, thus heating the propellant and providing thrust through a suitably designed nozzle and expansion skirt. The specific impulse is limited only by the ability to adequately cool the thruster and the amount of laser energy entering the engine. The results of the study showed that, with advanced technology, laser rocket systems with either a space- or ground-based laser transmitter could reduce the national budget allocated to space transportation by 10 to 345 billion dollars over a 10-year life cycle when compared to advanced chemical propulsion systems (LO2-LH2) of equal capability. The variation in savings depends upon the projected mission model.

Jones, W. S.↗
DOE OSTI2024

Modelling of cracking during beam oscillation laser welding of a creep-resistant nickel alloy

During high power laser welding of Inconel 740H, horizontal solidification cracks form at locations between approximately 70–80% of the weld depth. With the integration of circular beam oscillation, the laser energy density distribution and underlying thermo-mechanical conditions were altered. By coupling three-dimensional heat transfer, fluid flow, and stress modelling tools, the role that circular beam oscillation plays in the formation of the strain rates and stresses driving this cracking phenomenon was identified. While the addition of a circular oscillation pattern appeared to lower the stress levels along the solidification front, it did not eliminate the appearance of horizontal cracking. Only when the beam amplitudes reached 1.6 mm did solidification cracking disappear, but the weld depths were also significantly reduced.

Gao, Mingze↗
NASA NTRS1993

The feasibility of producing aluminum-lithium structures for cryogenic tankage applications by laser beam welding

Aluminum-lithium alloys exhibit high strength, high elastic modulus, and low density as well as excellent cryogenic mechanical properties making them ideal material candidates for cryogenic tanks. NASA has proposed the use of 'built-up' structure for panels fabricated into cryogenic tanks replacing current conventional machining. Superplastically formed stiffeners would be joined to sheet (tank skin) that had been roll formed to the radius of the tank in order to produce panels. Aluminum-lithium alloys of interest for producing the built-up structure include alloy 2095-T6 stiffeners to 2095-T8 sheet and alloy 8090-T6 stiffeners to 2090-T83 sheet. Laser welding, with comparable joint properties, offers the following advantages over conventional welding: higher production rates, minimal degradation within the heat affected zones, and full process automation. This study established process parameters for laser beam welding, mechanical property determinations, metallographic characterization, and fabrication of prototype panels. Tensile tests representing partial penetration of the skin alloys provided joint efficiencies between 65 and 77 percent, depending upon alloy and degree of penetration. Results of tension shear tests of lap welds indicated that the combination of 2095-T6 to 2090-T8 exhibited significantly higher weld shear strength at the interface in comparison to welds of 8090-T6 to 2090-T83. The increased shear strength associated with 2095 is believed to be due to the alloy's ability to precipitation strengthening (naturally age) after welding.

Martukanitz, R. P.↗
NASA NTRS2010

Boundary Layer Measurements in a Supersonic Wind Tunnel Using Doppler Global Velocimetry

A modified Doppler Global Velocimeter (DGV) was developed to measure the velocity within the boundary layer above a flat plate in a supersonic flow. Classic laser velocimetry (LV) approaches could not be used since the model surface was composed of a glass-ceramic insulator in support of heat-transfer measurements. Since surface flare limited the use of external LV techniques and windows placed in the model would change the heat transfer characteristics of the flat plate, a novel approach was developed. The input laser beam was divided into nine equal power beams and each transmitted through optical fibers to a small cavity within the model. The beams were then directed through 1.6-mm diameter orifices to form a series of orthogonal beams emitted from the model and aligned with the tunnel centerline to approximate a laser light sheet. Scattered light from 0.1-micron diameter water condensation ice crystals was collected by four 5-mm diameter lenses and transmitted by their respective optical fiber bundles to terminate at the image plane of a standard two-camera DGV receiver. Flow measurements were made over a range from 0.5-mm above the surface to the freestream at Mach 3.51 in steady state and heat pulse injected flows. This technique provides a unique option for measuring boundary layers in supersonic flows where seeding the flow is problematic or where the experimental apparatus does not provide the optical access required by other techniques.

Meyers, James F.↗
DOE OSTI2021

Hohlraum x-ray preheat asymmetry measurement at the ICF capsule via Mo ball fluorescence imaging

In inertial confinement fusion, penetrating asymmetric hohlraum preheat radiation (>1.8 keV, which includes high temperature coronal M-band emission from laser spots) can lead to asymmetric ablation front and ablator–fuel interface hydrodynamic instability growth in the imploding capsule. First experiments to infer the preheat asymmetries at the capsule were performed on the National Ignition Facility for high density carbon (HDC) capsules in low density fill (0.3 mg/cc 4He) Au hohlraums by time resolved imaging of 2.3 keV fluorescence emission of a smaller Mo sphere placed inside the capsule. Measured Mo emission is pole hot (P2 > 0) since M-band is generated mainly by the outer laser beams as their irradiance at the hohlraum wall is 5× higher than for the inner beams. P2 has a large swing vs time, giving insight into the laser heated hohlraum dynamics. P4 asymmetry is small at the sphere due to efficient geometric smoothing of hohlraum P4 asymmetries at large hohlraum-to-capsule radii ratios. The asymmetry at the HDC capsule is inferred from the Mo emission asymmetry accounting for the Mo/HDC radius difference and HDC capsule opacity.

Dewald, E. L. (ORCID:0000000340546967)↗
NASA NTRS1970

Laser heating of ionized helium

High energy density plasma generation by heating He gas to high temperatures with electric discharge and focused ruby laser beam

Scherrer, V. E.↗
NASA NTRSDate not supplied

Comparative Study of Additively Manufactured Inconel 625 In the As-Built and Heat-Treated Condition

This study was conducted to characterize the microstructure and mechanical properties of Inconel 625 manufactured with laser powder bed fusion (L-PBF), electron beam melting (EBM), wire arc additive manufacturing (WAAM), electron beam directed energy deposition (EB-DED), laser powder directed energy deposition (LP-DED), and laser wire directed energy deposition (LW-DED) in both the as built and heat-treated condition. The heat treatment in this study included stress relieving, hot isostatic pressure (HIP), and solution treatment. The effects of the heat treatment on the grain widths and hardness of the alloy will be observed across the technologies before and after heat-treatment. At the end of this study there will be a comparative analysis of the alloy Inconel 625 across the six technologies.

V Luna↗
DOE OSTI2022

Inferring Heat Flow in Laser Absorption Regions using Diagnostic Magnetic Fields

This research was motivated by the desire to obtain a measurement of heat-flow in overdense regions of a laser ablated plasma for the first time using a high energy proton beam. For sufficiently high energies, the proton beam can pass through overdense regions and only be deflected by electric and magnetic fields. As the transport of magnetic fields in a plasma are intrinsically linked to the transport of thermal energy, it was posited that such a measurement could be used to infer a heat-flow. While the project did not prove the method to be infeasible, difficulties with understanding the proton radiographs without an imposed magnetic field made the final aim of this project unreached. Instead, however, a closer understanding of proton radiographs of laser-solid interactions without an imposed field has been obtained. 5 shot days on The OMEGA Laser Facility have been awarded (3 through ICF and 2 as ride-along) to further investigate some of these features. Extrapolating current results to hohlraum conditions has the magnetic energy being a significant (10%) fraction of the laser drive energy, which has the potential to explain the NIF hohlraum drive deficit.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Inferring Heat Flow in Laser Absorption Regions using Diagnostic Magnetic Fields: Abstract

This research was motivated by the desire to obtain a measurement of heat-flow in overdense regions of a laser ablated plasma for the first time using a high energy proton beam. For sufficiently high energies, the proton beam can pass through overdense regions and only be deflected by electric and magnetic fields. As the transport of magnetic fields in a plasma are intrinsically linked to the transport of thermal energy, it was posited that such a measurement could be used to infer a heat-flow. While the project did not prove the method to be infeasible, difficulties with understanding the proton radiographs without an imposed magnetic field made the final aim of this project unreached. Instead, however, a closer understanding of proton radiographs of laser-solid interactions without an imposed field has been obtained. 5 shot days on The OMEGA Laser Facility have been awarded (3 through ICF and 2 as ride-along) to further investigate some of these features. Extrapolating current results to hohlraum conditions has the magnetic energy being a significant (10%) fraction of the laser drive energy, which has the potential to explain the NIF hohlraum drive deficit.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1972

Laser propulsion

The use of an earth-based high-power laser beam to provide energy for earth-launched rocket vehicle is investigated. The laser beam energy is absorbed in an opaque propellant gas and is converted to high-specific-impulse thrust by expanding the heated propellant to space by means of a nozzle. This laser propulsion scheme can produce specific impulses of several thousand seconds. Payload to gross-weight fractions about an order of magnitude higher than those for conventional chemical earth-launched vehicles appear possible. There is a potential for a significant reduction in cost per payload mass in earth orbit.

Rom, F. E.↗
NASA NTRS1977

Thermoelectronic laser energy conversion for power transmission in space

Long distance transmission of power in space by means of laser beams is an attractive concept because of the very narrow beam divergence. Such a system requires efficient means to both generate the laser beam and to convert the light energy in the beam into useful electric output at the receiver. A plasma-type device known as a Thermo-Electronic Laser Energy Converter (TELEC) has been studied as a method of converting a 10.6 micron CO2 laser beam into electric power. In the TELEC process, electromagnetic radiation is absorbed directly in the plasma electrons producing a high electron temperature. The energetic electrons diffuse out of the plasma striking two electrodes with different areas. Since more electrons are collected by the larger electrode there is a net transport of current, and an EMF is generated in the external circuit. The smaller electrode functions as an electron emitter to provide continuity of the current. Waste heat is rejected from the large electrode. A design for a TELEC system with an input 1 MW laser beam was developed as part of the study. The calculated performance of the system showed an overall efficiency of about 42%.

Britt, E. J.↗
DOE OSTI2024

Clarifying the formation of equiaxed grains and microstructural refinement in the additive manufacturing of Ti-Cu

Controlling microstructural evolution in metallic additive manufacturing (AM) is difficult, especially in producing refined as-built grains instead of coarse, directional grains. Traditional solutions involve adding inoculants to AM feedstocks, but titanium (Ti) alloys cannot employ this approach without producing detrimental secondary phases. Ti-Cu (Ti-copper) alloys offer a solution through constitutional supercooling and/or solid state thermal cycling under AM conditions. This work analyzes a compositionally graded directed energy deposition (DED) Ti-Cu build, single-melt laser tracks, and dilatometric heat treatments to evaluate if, when, and by what mechanism(s) microstructural refinement occurs. Refinement by inoculation of unmelted powder particles was also considered. Constitutional supercooling produced no net microstructural refinement as any equiaxed dendrites which form are remelted with new deposition. This finding agreed with solidification modeling of powder bed fusion-laser beam (PBF-LB) and DED builds. Solid state thermal cycling refined microstructures only during ex-situ dilatometric heat treatments, suggesting build parameter optimization is needed to achieve refinement in-situ. Accidental heterogeneous nucleation on unmelted Ti powder, originating from the different thermophysical properties of Ti and Cu, provided the most significant microstructural refinement. This work systematically assesses the microstructural refinement mechanisms of Ti-Cu in AM builds and offers insights into microstructural control in eutectoid alloys.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Monitoring Delamination of Thermal Barrier Coating During Interrupted High-Heat Flux Laser Testing Using Upconversion Luminescence Imaging

Upconversion luminescence imaging of thermal barrier coatings (TBCs) has been shown to successfully monitor TBC delamination progression during interrupted furnace cycling. However, furnace cycling does not adequately model engine conditions where TBC-coated components are subjected to significant heat fluxes that produce through-thickness temperature gradients that may alter both the rate and path of delamination progression. Therefore, new measurements are presented based on luminescence imaging of TBC-coated specimens subjected to interrupted high-heat-flux laser cycling exposures that much better simulate the thermal gradients present in engine conditions. The TBCs tested were deposited by electron-beam physical vapor deposition (EB-PVD) and were composed of 7wt% yttria-stabilized zirconia (7YSZ) with an integrated delamination sensing layer composed of 7YSZ co-doped with erbium and ytterbium (7YSZ:Er,Yb). The high-heat-flux exposures that produce the desired through-thickness thermal gradients were performed using a high power CO2 laser operating at a wavelength of 10.6 microns. Upconversion luminescence images revealed the debond progression produced by the cyclic high-heat-flux exposures and these results were compared to that observed for furnace cycling.

Eldridge, Jeffrey I.↗