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At least 1,639 records · Page 91

Principles of Directed Energy Deposition for Aerospace Applications

Metal Additive Manufacturing is changing how components are being fabricated for rocket propulsion and aerospace applications. Many additive manufacturing technologies are evolving, and active research is being conducted across academia, industry, and government to advance processes, materials, design, post-processing, and applications. While much focus has been on Laser Powder Bed Fusion (L-PBF) techniques, several large-scale techniques are also rapidly evolving using directed energy deposition (DED) techniques. This lecture will provide an overview of various DED technologies, a comparison among the technologies, various materials, parameters used to deposit, and several examples of DED applications for propulsion and aerospace components.

Additive Manufacturing↗

Design and Fabrication of a Temperature-Controlled Fueled Molten Salt Capsule Irradiation Experiment

Idaho National Laboratory (INL) is developing a Molten salt Research Temperature-controlled Irradiation (MRTI) experimental capsule for the Neutron Radiography (NRAD) reactor. The experiment is envisaged to be versatile and able to host a variety of salt-wall material combinations. The first test is designed to contain actinide-bearing chloride salt, which previously has not been subjected to a neutron field. The main objectives of the experiment are to produce irradiated salt samples for Post Irradiation Examination (PIE), to evaluate salt behavior under irradiation, and to test in-situ sensors/instrumentation. The final design for the experiment completed in 2022, and fabrication of the experiment is underway. The salt is double encapsulated providing insulation and redundancy in the case of leakage. A gas-gap between the inner capsule and the outer container enables tuning of thermal conduction to the NRAD coolant by altering its thickness and its gas-mixture. An inert gas mixture ratio in the gas-gap ensures the configurations reached a targeted average salt temperature of 600oC, while avoiding salt freezing or exceeding material limits. A resistive heater placed within a thermowell and controls the temperature of the experiment (both when the reactor is on or off). The selected configurations can contain over 10 cm3 of fuel-bearing chloride salt, which is sufficient for the purposes of the post-irradiation examination (PIE) and provides sufficient volume for two submerged thermocouple probes to monitor salt temperature. The capsule wall material is Inconel 625, and weld qualifications for the assembly have been developed. A glove-box laser weld technique was refined as part of this process to ensure a leak-tight assembly for the salt-bearing assembly and reduce the risks of impurities permeating into the salt. This work was supported through the INL Laboratory Directed Research & Development (LDRD) Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

ENYGF 2023 - Design of Temperature-controlled Fuel-salt Irradiation Experiment

Idaho National Laboratory (INL) is developing a Molten salt Research Temperature-controlled Irradiation (MRTI) experimental capsule for the Neutron Radiography (NRAD) reactor. The experiment is envisaged to be versatile and able to host a variety of salt-wall material combinations. The first test is designed to contain actinide-bearing chloride salt, which previously has not been subjected to a neutron field. The main objectives of the experiment are to produce irradiated salt samples for Post Irradiation Examination (PIE), to evaluate salt behavior under irradiation, and to test in-situ sensors/instrumentation. The final design for the experiment completed in 2022, and fabrication of the experiment is underway. The salt is double encapsulated providing insulation and redundancy in the case of leakage. A gas-gap between the inner capsule and the outer container enables tuning of thermal conduction to the NRAD coolant by altering its thickness and its gas-mixture. An inert gas mixture ratio in the gas-gap ensures the configurations reached a targeted average salt temperature of 600oC, while avoiding salt freezing or exceeding material limits. A resistive heater placed within a thermowell and controls the temperature of the experiment (both when the reactor is on or off). The selected configurations can contain over 10 cm3 of fuel-bearing chloride salt, which is sufficient for the purposes of the post-irradiation examination (PIE) and provides sufficient volume for two submerged thermocouple probes to monitor salt temperature. The capsule wall material is Inconel 625, and weld qualifications for the assembly have been developed. A glove-box laser weld technique was refined as part of this process to ensure a leak-tight assembly for the salt-bearing assembly and reduce the risks of impurities permeating into the salt. This work was supported through the INL Laboratory Directed Research & Development (LDRD) Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

X-ray tomography of damage dynamics in advanced materials using a laser wakefield accelerator

Additively manufactured (AM) metals offer the potential for customizable, cost-effective components, but qualification and certification are crucial. Key to this process is understanding pore dynamics under stress, typically analyzed using micro-computed tomography. This study introduces laboratory-scale “betatron” x-rays from laser wakefield acceleration as a high-throughput alternative for x-ray tomography of advanced materials, such as AM AlSi10Mg alloys. Coupled with 3D finite element modeling, this method provides detailed insights into stress-porosity interactions. The approach delivers high-resolution scans, revealing that pore shape and local triaxiality significantly influence fracture dynamics, supporting advanced material characterization. This work also demonstrates the potential and versatility of laser-betatron x-ray μCT for generating large datasets to accelerate our understanding of the stochastic, process-specific nature of pore formation in AM alloys.

Senthilkumaran, Vigneshvar↗

Martian Buried Basins and Implications for Characteristics of the Burial Layer and Underlying Surface

Deciphering the cratering record on Mars has been challenging because it may reflect the changes in both the population of impactors and in the resurfacing processes on Mars. However, it is possible to determine the breadth of impactors captured in the cratering record. Extensive areas of resurfacing are of particular interest because they likely contain material from various ages in Martian history. By deducing the impact populations in both surface and underlying layers of terrain, it is possible to determine the age of the layers and constrain theories on the development of the Martian surface. However, to do so requires a method of seeing impact features which are no longer visible. Topographic data of Mars, taken by the Mars Orbiter Laser Altimeter (MOLA), has revealed impact features buried by resurfacing processes. These features are often indistinguishable on Viking images of the Martian surface. In this study, gridded MOLA data was analyzed in order to locate buried impact features, also called buried basins, in Syria, Solis, and Sinai Planum just south of Valles Marineris. The population statistics of buried features can be compared to those of visible features in order to determine the age of the underlying material and characteristics of the surface cover. Specifically, if the buried population in the Hesperian terrain is similar to the population of visible features in the Noachian, it would suggest that the underlying terrain is Noachian in age. The buried craters can then be compared to visible Noachian craters to reveal the amount of deterioration of the buried features. These comparisons allow us to explore the morphology of the terrain in the Hesperian region to determine if topographic variations are due to differences in the thickness of the overlying material or are a characteristic of the underlying terrain.

Sarid, A. R.↗

Femtosecond Laser Additive Manufacturing of Multi-Material Layered Structures

Laser additive manufacturing (LAM) of a multi-material multi-layer structure was investigated using femtosecond fiber lasers. A thin layer of yttria-stabilized zirconia (YSZ) and a Ni–YSZ layer were additively manufactured to form the electrolyte and anode support of a solid oxide fuel cell (SOFC). A lanthanum strontium manganite (LSM) layer was then added to form a basic three layer cell. This single step process eliminates the need for binders and post treatment. Parameters including laser power, scan speed, scan pattern, and hatching space were systematically evaluated to obtain optimal density and porosity. This is the first report to build a complete and functional fuel cell by using the LAM approach.

36 MATERIALS SCIENCE↗

Raman-shifting an ArF excimer laser to generate new lines for obtaining optical diagnostic based information in flow fields

The application of tunable excimer lasers in combustion and flow diagnostics is almost routine nowadays. The properties of this laser system that enable density and temperature measurements in supersonic and hypersonic flow fields to be conducted are its high power, high repetition rate, and high spectral brightness. The limitation imposed by this system on these measurements is the paucity of lines in the wavelength region, the vacuum-ultraviolet, where species of interest, such as OH, N2, O2, H2, H2O, CO, NO, etc., are susceptible to electronic excitation to high-lying states. To circumvent this problem one normally resorts to nonlinear optical techniques such as frequency conversion via stimulated Raman scattering (SRS), more commonly known as Raman shifting or Raman mixing, to extend these nonintrusive and nonperturbing techniques to the shorter wavelengths in the VUV region and, for that matter, to longer wavelengths in the infrared region, if the need arises. The theoretical basis of SRS and its application are well documented in the literature. In essence, the Raman shift is a consequence of the inelastic scattering of the incident radiation by the sample. Most of the scattered radiation from the molecules of the sample is unchanged in frequency. However, a small fraction of the incident radiation is changed in frequency. This shift is a result of the fact that some of the incident photons on colliding with the molecules of the sample give up some of their energy and emerge with a lower energy resulting in the lower-frequency Stokes radiation. Other incident photons may increase their energy by colliding with the vibrationally excited molecules of the medium and emerge as higher-frequency antistokes radiation. The generation of the latter is the main objective of this project. The process, however, depends on several factors, including the beam quality of the pump laser, the cross-section of the gaseous medium, the gas pressure, and the ambient temperature of the gas near the focal region. Furthermore, since the Raman shifting process is polarization sensitive, it is necessary to have all of the laser energy in a single polarization. These factors were taken into consideration in the execution of the project. The implementation of the Raman shift was accomplished by focusing the 193 nm output of an ArF excimer laser (Lamda-Physik LPX 150) into a 1-meter long high pressure recirculating Raman cell filled with H2 gas. The laser system was modified in order to improve the mode quality of the pump beam to enhance the Raman shifting. To accomplish this feat, a prism beam expander and grating on the oscillator discharge provided wavelength tuning over the excimer gain profile. Furthermore, a triple-pass configuration, as opposed to unstable resonator optics, was employed in the operation of the amplifier cavity so that when the oscillator output radiation, focused by a 51-cm focal length fused silica lens through a 50 micron pinhole (serving as a spatial filter) and recollimated with a 25-cm focal length lens, was fed into the amplifier, it was injection locked, thereby providing tunable radiation with relatively low divergence. The forward scattered radiation emanating from the impingement of the modified pump beam on the Raman cell was detected using an energy meter after the latter had been separated from it using a dispersing prism.

Koker, Edmond B.↗

An extended-source spatial acquisition process based on maximum likelihood criterion for planetary optical communications

This paper describes an extended-source spatial acquisition process based on the maximum likelihood criterion for interplanetary optical communications. The objective is to use the sun-lit Earth image as a receiver beacon and point the transmitter laser to the Earth-based receiver to establish a communication path. The process assumes the existence of a reference image. The uncertainties between the reference image and the received image are modeled as additive white Gaussian disturbances. It has been shown that the optimal spatial acquisition requires solving two nonlinear equations to estimate the coordinates of the transceiver from the received camera image in the transformed domain. The optimal solution can be obtained iteratively by solving two linear equations. Numerical results using a sample sun-lit Earth as a reference image demonstrate that sub-pixel resolutions can be achieved in a high disturbance environment. Spatial resolution is quantified by Cramer-Rao lower bounds.

Yan, Tsun-Yee↗

Laser-induced fluorescence detection strategies for sodium atoms and compounds in high-pressure combustors

A variety of laser-induced fluorescence schemes were examined experimentally in atmospheric pressure flames to determine their use for sodium atom and salt detection in high-pressure, optically thick environments. Collisional energy transfer plays a large role in fluorescence detection. Optimum sensitivity, at the parts in 10 exp 9 level for a single laser pulse, was obtained with the excitation of the 4p-3s transition at 330 nm and the detection of the 3d-3p fluorescence at 818 nm. Fluorescence loss processes, such as ionization and amplified spontaneous emission, were examined. A new laser-induced atomization/laser-induced fluorescence detection technique was demonstrated for NaOH and NaCl. A 248-nm excimer laser photodissociates the salt molecules present in the seeded flames prior to atom detection by laser-induced fluorescence.

Weiland, Karen J. R.↗

Apparatus and Method for Elimination of Polarization-Induced Fading in Fiber-optic Sensor System

The invention is an apparatus and method of eliminating polarization-induced fading in interferometric fiber-optic sensor system having a wavelength-swept laser optical signal. The interferometric return signal from the sensor arms are combined and provided to a multi-optical path detector assembly and ultimately to a data acquisition and processing unit by way of a switch that is time synchronized with the laser scan sweep cycle.

Chan, Hon Man↗

Testing the Efficacy of Laser Sterilization as A Spacecraft Bioburden Reduction Alternative

As NASA continues to put forth efforts in seeking out life in the solar system with missions like Europa Clipper, Mars Sample Return, and Dragonfly, reducing the bioburden (number of living microbes) on spacecraft is required by NASA policy for the protection of potentially habitable worlds. In this project, we are testing the efficacy of a novel method for laser sterilization on stress tolerant bacterial spores (Bacillus subtilis) using a high energy femtosecond laser. To test the laser, we inoculate metal coupons with Bacillus subtilis spores. After laser treatment, we do a PVA (polyvinyl acetate) peel to recover the spores then we calculate to find the number of spores that survived the treatment. Our results show that within a certain pulse count range, increasing fluence increases sterilization effectiveness. We have demonstrated the ability to reduce viable microbial counts by at least 10-4. By studying laser sterilization, we could change the way spacecraft are sterilized by making the process more efficient and cost-effective.

Planetary protection↗

Video-Camera-Based Position-Measuring System

A prototype optoelectronic system measures the three-dimensional relative coordinates of objects of interest or of targets affixed to objects of interest in a workspace. The system includes a charge-coupled-device video camera mounted in a known position and orientation in the workspace, a frame grabber, and a personal computer running image-data-processing software. Relative to conventional optical surveying equipment, this system can be built and operated at much lower cost; however, it is less accurate. It is also much easier to operate than are conventional instrumentation systems. In addition, there is no need to establish a coordinate system through cooperative action by a team of surveyors. The system operates in real time at around 30 frames per second (limited mostly by the frame rate of the camera). It continuously tracks targets as long as they remain in the field of the camera. In this respect, it emulates more expensive, elaborate laser tracking equipment that costs of the order of 100 times as much. Unlike laser tracking equipment, this system does not pose a hazard of laser exposure. Images acquired by the camera are digitized and processed to extract all valid targets in the field of view. The three-dimensional coordinates (x, y, and z) of each target are computed from the pixel coordinates of the targets in the images to accuracy of the order of millimeters over distances of the orders of meters. The system was originally intended specifically for real-time position measurement of payload transfers from payload canisters into the payload bay of the Space Shuttle Orbiters (see Figure 1). The system may be easily adapted to other applications that involve similar coordinate-measuring requirements. Examples of such applications include manufacturing, construction, preliminary approximate land surveying, and aerial surveying. For some applications with rectangular symmetry, it is feasible and desirable to attach a target composed of black and white squares to an object of interest (see Figure 2). For other situations, where circular symmetry is more desirable, circular targets also can be created. Such a target can readily be generated and modified by use of commercially available software and printed by use of a standard office printer. All three relative coordinates (x, y, and z) of each target can be determined by processing the video image of the target. Because of the unique design of corresponding image-processing filters and targets, the vision-based position- measurement system is extremely robust and tolerant of widely varying fields of view, lighting conditions, and varying background imagery.

Lane, John↗

Unveiling the Mechanism of Photodamage to Sphingolipid Molecules via Laser Flash Photolysis and EPR

Abstract Sphingolipids are involved in the maintenance of the skin barrier function and regulate cellular processes of keratinocytes. The work reported here is designed to uncover details of the mechanism of damage to such lipids by UV radiation. Our approach employs laser flash photolysis and electron paramagnetic resonance (EPR) spectrometry to explore the mechanism of the decay reactions, and to determine the associated kinetic parameters. To interpret our experiments, we computed both excitation energies and EPR parameters of radicals formed during photolysis. Employing the spin‐trap EPR method confirmed the formation of both carbon‐ and nitrogen‐centered radicals. Thus, we can conclude that the photodecomposition of sphingolipids and their analogues proceeds by Norrish type I reactions with the formation of both nitrogen‐centered and alkyl radicals.

Biochemistry & Molecular Biology↗

Understanding Weld Formation and Microstructure Evolution in Laser Welded Stainless Steels and Ti-6Al-4V

High energy density welding processes are used for many industrial applications, such as aerospace and defense, and certain joint configurations and welding situations render post-weld inspection techniques difficult. Due to the inability to confirm penetration, there is a continual industrial need to improve prediction capabilities to aid in parameter selection. It is also necessary to understand the microstructural evolution to modify phase fractions and mitigate weldability related concerns such as solidification cracking or reduced corrosion performance.

42 ENGINEERING↗

Digital image processing of flow visualization photographs

This paper is concerned with the propagation of laser light through a slab of a randomly varying medium. A theoretical analysis is presented which relates the spectrum of the recorded-intensity field some distance downstream of the medium to the spectrum of the index-of-refraction field. For a homogeneous and isotropic random field, the 3-D spectrum of the medium is obtained from the 2-D spectrum of the photograph by dividing each component of the spectrum by the frequency raised to the fourth power. Free-space propagation outside the random medium is accounted for by a scaling factor. Experimental results are presented which support the theoretical analysis. The nonintrusive diagnostic technique presented here is applicable to photographs which contain partially developed caustic networks.

Hesselink, L.↗

Particle sizing in rocket motor studies utilizing hologram image processing

A technique of obtaining particle size information from holograms of combustion products is described. The holograms are obtained with a pulsed ruby laser through windows in a combustion chamber. The reconstruction is done with a krypton laser with the real image being viewed through a microscope. The particle size information is measured with a Quantimet 720 image processing system which can discriminate various features and perform measurements of the portions of interest in the image. Various problems that arise in the technique are discussed, especially those that are a consequence of the speckle due to the diffuse illumination used in the recording process.

Netzer, David↗

Cross-beam energy transfer in direct-drive ICF. II. Theory and simulation of mitigation through increased laser bandwidth

The response of the cross-beam energy transfer instability (CBET) to laser bandwidth is investigated through a combination of theory and simulation. Existing linear theory is generalized to treat broadband lasers, demonstrating that CBET is most effectively suppressed when the bandwidth exceeds the ion-acoustic wave (IAW) frequency. It is shown that for such bandwidths, reverse (seed to pump) transfer becomes possible, which reduces the net energy transfer rapidly as bandwidth is increased. The CBET gain exponent in this regime scales with bandwidth (Δω) as Δω−3 for Gaussian or Lorentzian laser spectra with different scalings possible for other spectra. Comparison of our theory with linearized fluid and particle-in-cell simulations, performed with the laser-plasma simulation environment (LPSE) and vector particle in cell (VPIC) codes, respectively, finds that the model is accurate in the absence of nonlinear processes. However, linear analysis also finds that the IAW energy density scales as Δω−1, implying that nonlinear effects may be more difficult to control than the CBET scaling would suggest. Indeed, nonlinear effects are found to be present in VPIC simulations with high-intensity lasers, despite minimal apparent CBET. Nonlinear processes in the VPIC cases include particle trapping, the two-ion wave decay, and ion wave self-focusing. In some high intensity VPIC cases, these effects lead to net energy transfer from seed to pump and increases to backscatter stimulated Brillouin scattering reflectivities. Finally, for a given bandwidth, we show that improved control of nonlinear processes can be achieved via smoothing by spectral dispersion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗