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All sources NASA NTRS DOE OSTI

DOE OSTI2020

Binderjet Additive Manufacturing for Complex Heat Exchanger Geometries

Concentrated Solar Power (CSP) systems play a role in the worlds development of renewable energy. Mirrors are used to concentrate sunlight that is converted into electricity or other forms of useful energy. CSP impact depends significantly on its overall economics. The U.S. Department of Energy’s (DOE’s) Solar Energy Technology Office (SETO) cost goals for 2030include $0.05/kWh levelized cost of electricity (LCOE) for a baseload plant [1]. The power cycle cost goal is $900/kWe [1]. The envisioned recompression supercritical carbondioxide (sCO2) power cycle includes four heat exchangers, which together are at least ¾ of the total power cycle cost. Meeting the cost target requires reducing the heat exchanger cost. The 260 bar and 588 °C heat exchanger requirements are challenging. Shell and tube heat exchangers can meet the requirements, but the size and cost are prohibitive. State-of-the-art diffusion bonded printed circuit heat exchanger designs are 3 m3 or larger and expensive to manufacture. Additive manufacturing enables novel heat exchanger geometries that can reduce heat exchanger size and mass [2]. Binderjet technology is an additive manufacturing modality. It selectively deposits binder material onto the powder bed to form a solid part one layer at a time. Once applied, the binder is cured, the remaining powder removed, and the part heat treated in steps to remove the binder, sinter the metal powder, and densify the part. The Binderjet printing process is more than 10x faster than the best-known metal additive modality, direct metal laser melting (DMLM), thus enabling 10x the part through-put rate [3]. The high throughput rate results in a low-cost manufacturing process capable of creating complex heat exchanger geometries. This paper introduces a complex heat exchanger geometry and methods of Binderjet processing to fabricate the geometry.

Barua, Ananda↗

NASA NTRS2023

Additive Manufacturing of Oxide Dispersion Strengthened Multi Principle Element Alloys for Future Aerospace Applications

Oxide Dispersion Strengthened (ODS) materials have long been of interest for their high temperature applications, and additive manufacturing enables their manufacturing viability. The ODS multi-principle element alloy NiCoCr was prepared using powder metallurgy techniques, additively manufactured, and evaluated for its processingmicrostructure-property relationships. The high temperature foundations of nickel-base superalloys and ODS materials were combined with the manufacturing advantages of 3D printing and the chemical simplicity of NiCoCr to inspire this work, which was divided into powder and printed material assessments. The project was achieved through multiple iterative project loops to assess the processing parameters’ impact on the microstructure and mechanical properties of the feedstock powder and printed material. The powder investigations (Chapter 3) focused on understanding the oxide coating that formed on the metal powder following acoustic mixing. Time of Flight Secondary Ion Mass Spectrometry was used to semi-quantitatively assess the amount of yttrium on the surface of the mixed powders, and indicated that a combination of higher mixing condition energy and moderate mixing time resulted in the most oxide coating on the NiCoCr powder. The results were supported by a qualitative assessment of scanning electron images of coated powder particles. Following mixing, the ODS NiCoCr was consolidated by Laser Powder Bed Fusion. The evaluations of the printed material (Chapter 4) frst considered screening experiments including Archimedes’ density, porosity, and grain size and number metrics from electron backscatter diffraction data. After the ideal additive manufacturing parameters were identifed, both the oxide homogeneity and yield strength were discussed for the idealized printed material. Overall, the project suggests that the combined use of qualitative or semi-quantitative powder surface analysis with Archimedes’ density analyses can be a valid high-throughput technique which can lead to process optimization of Laser Powder Bed Fusion additively manufactured ODS material.

Laura G Wilson↗

DOE OSTI2025

Relativistic Laser Plasma Interactions At The Highest Intensities

High energy density science (HEDS) explores the nature of matter under extreme conditions of temperature and pressure. It is of fundamental importance and has many applications such as facilitating imaging with ions, neutrons, x-rays, and gamma rays with new applications being developed, including materials processing and medical therapies. In this project, we used high power, ultrashort pulse lasers to reach HEDS conditions. We have shown that low-cost, liquid crystal film based, double plasma mirror systems can be used to greatly improve laser pulse contrast while still maintaining high power and excellent spatial mode.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Pulsed photoemission induced plasma breakdown

Abstract This article characterises the effects of cathode photoemission leading to electrical discharges in an argon gas. We perform breakdown experiments under pulsed laser illumination of a flat cathode and observe Townsend to glow discharge transitions. The breakdown process is recorded by high-speed imaging, and time-dependent voltage and current across the electrode gap are measured for different reduced electric fields and laser intensities. We employ a 0D transient discharge model to interpret the experimental measurements. The fitted values of transferred photoelectron charge are compared with calculations from a quantum model of photoemission. The breakdown voltage is found to be lower with photoemission than without. When the applied voltage is insufficient for ion-induced secondary electron emission to sustain the plasma, laser driven photoemission can still create a breakdown where a sheath (i.e. a region near the electrode surfaces consisting of positive ions and neutrals) is formed. This photoemission induced plasma persists and decays on a much longer time scale ( ∼ 10 s μ s) than the laser pulse length ( 30 ps). The effects of different applied voltages and laser energies on the breakdown voltage and current waveforms are investigated. The discharge model can accurately predict the measured breakdown voltage curves, despite the existence of discrepancy in quantitatively describing the transient discharge current and voltage waveforms.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2006

Optical Profilometers Using Adaptive Signal Processing

A method of adaptive signal processing has been proposed as the basis of a new generation of interferometric optical profilometers for measuring surfaces. The proposed profilometers would be portable, hand-held units. Sizes could be thus reduced because the adaptive-signal-processing method would make it possible to substitute lower-power coherent light sources (e.g., laser diodes) for white light sources and would eliminate the need for most of the optical components of current white-light profilometers. The adaptive-signal-processing method would make it possible to attain scanning ranges of the order of decimeters in the proposed profilometers.

Hall, Gregory A.↗

DOE OSTI2020

Imaging Supramolecular Morphogenesis with Confocal Laser Scanning Microscopy at Elevated Temperatures

The morphogenesis of supramolecular assemblies is a highly dynamic process that has only recently been recognized, and our understanding of this phenomenon will require imaging techniques capable of crossing scales. Shape transformations depend both on the complex energy landscapes of supramolecular systems and the kinetically controlled pathways that define their structures and functions. We report here the use of confocal laser scanning microscopy coupled with a custom-designed variable-temperature sample stage that enables in situ observation of such shape changes. The submicrometer resolution of this technique allows for real-time observation of the nanostructures in the native liquid environments in which they transform with thermal energy. We use this technique to study the temperature-dependent morphogenic behavior of peptide amphiphile nanofibers and photocatalytic chromophore amphiphile nanoribbons. Furthermore, the variable-temperature confocal microscopy technique demonstrated in this work can sample a large volume and provides real-time information on thermally induced morphological changes in the solution.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Alignment and dissociation of electronically excited molecular hydrogen with intense laser fields

The dissociation of aligned, electronically excited H 2 (E,F 1 Σ g + ), followed by ionization of the produced H atom, is analyzed via the velocity mapped imaging technique. The dissociation and ionization processes are accomplished, respectively, by a two- and a onephoton absorption from a single 532-nm laser pulse, while the alignment is induced by a separate 1064-nm laser pulse. The velocity of the produced H + photofragments shows a weak perpendicular alignment at low alignment laser field values, evolving to strongly parallel for larger fields. We modeled this alignment behavior with a simple two-state model involving the Stark mixing of the initially-prepared J = 0 with the J = 2 rotational state. This model is able to reproduce all of the observed angular distribution, and permits us to extract from the fit the polarizability anisotropy of H 2 (E,F) electronic state. We determine this value to be (3.7 ± 1.2) x 10 3 a.u. As this value is extremely large in comparison to what one would expect from the pure H 2 (E,F) electronic state, we hypothesize that this value comes from the 1064-nm laser beam mixing nearby electronic states with the initially laser prepared (E,F) state generating a mixed state (EF**) with an extremely large polarizability anisotropy.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2025

Ink-based laser powder bed fusion of barium titanate

Barium titanate (BTO) is a lead-free functional ceramic that is widely used in sensors, transducers, and actuators. The increasing demand for complex geometries and quick design iterations motivates the use of additive manufacturing techniques. Laser powder bed fusion (L-PBF) additive manufacturing technique enables the net-shape or near-net-shape fabrication of metals and alloys. Ceramic L-PBF remains challenging due to their high melting temperature. Here, to address this challenge, a nanoparticle ink feedstock was incorporated into the L-PBF process to allow low power melting of BTO. Key print parameters (i.e. laser power, scanning speed, and hatching spacing) were optimized to fabricate millimeter-scale BTO parts. The printed BTO samples possessed an inhomogeneous equiaxed-columnar-cellular microstructure. Semiconducting current-voltage behavior was observed in as-printed samples, which was attributed to the creation of oxygen vacancies. The piezoelectric d 33 coefficient was measured to be 4.6 pC/N.

Dielectrics↗

NASA NTRS1977

The remote measurement of tornado-like flows employing a scanning laser Doppler system

The paper deals with a scanning laser Doppler velocimeter system employed in a test program for measuring naturally occurring tornado-like phenomena, known as dust devils. A description of the system and the test program is followed by a discussion of the data processing techniques and data analysis. The system uses a stable 15-W CO2 laser with the beam expanded and focused by a 12-inch telescope. Range resolution is obtained by focusing the optical system. The velocity of each volume of air (scanned in a horizontal plane) is determined from spectral analysis of the heterodyne signal. Results derived from the measurement program and data/system analyses are examined.

Jeffreys, H. B.↗

NASA NTRS1995

Laser Doppler Velocimetry and full-field soot volume fraction

Since its introduction in the mid-sixties, Laser Doppler Velocimetry (LDV) has become one of the most widely used methods for the measurement of flows. Its remote and essentially non-intrusive nature provides an invaluable tool for a variety of difficult measurement situations which would be otherwise inaccessible. The high spatial resolution and rapid temporal response afforded by this technique are well suited to the determination of spatial and temporal details of flow fields, as well as characterization of turbulence. Advances in the understanding of the properties of LDV signals, accompanied by technological advances in coherent laser sources, detectors of high sensitivity and low noise, optical fabrication techniques and high-speed digital signal processing architectures have resulted in systems of increased accuracy and flexibility. As will be shown, recent progress in solid-state lasers and photo-detectors has been beneficial insofar as the compatibility of this method with the unique and severe constraints inherent in microgravity combustion science experiments.

Greenberg, Paul S.↗

DOE OSTI2024

Process parameter translation strategies for variable directed energy deposition spot size using 316L, copper, and Inconel 625

Directed energy deposition (DED) is a form of additive manufacturing available across a variety of laser spot diameter values, often referred to as spot sizes. However, there is no method to easily transfer process parameters across discrete spot sizes, leading to DED process parameters that are equipment specific and not widely applicable. In this study, a strategy is proposed and investigated for five spot sizes that keep the areal energy density constant while varying power, feed rate, and powder flow during the deposition of 316L stainless steel. An assessment of trends in hardness and microstructure is possible due to the novel production of components of a single material across several spot sizes using a single nozzle on a single DED system. The proposed strategy was used to nullify the hardness drop during functional grading of Inconel 625 and pure copper, enabling fabrication of multi-material sample that does not compromise desirable properties. This application shows the value in establishing more efficient process parameter development and understanding spot size influences on geometric and material property flexibility, to enable a more diverse powder-based DED design space and to increase the industry adoption of DED systems.

316L↗

NASA NTRS1992

Definition and preliminary design of the LAWS (Laser Atmospheric Wind Sounder). Volume 1, phase 2: Executive summary

The objective of phase 1 of the LAWS study was to define and perform a preliminary design for the Laser Atmospheric Wind Sounder (LAWS) instrument. The definition phase consisted of identifying realistic concepts for LAWS and analyzing them in sufficient detail to be able to choose the most promising one for the LAWS application. System and subsystem configurations were then developed for the chosen concept. The concept and subsequent configurations were to be compatible with two prospective platforms--the Japanese Polar Orbiting Platform (JPOP) and as an attached payload on the Space Station Freedom. After a thorough and objective concept selection process, we chose a heterodyne detection Doppler lidar using a CO2 laser transmitter operating at 9.1 microns over a 2.1 micron solid state system. The choice of the CO2 approach over solid-state reflects the advanced state of development of CO2 lasers, its maturity in ground-based systems and the eased subsystem requirements associated with the longer wavelength. The CO2 lidar concept was then analyzed in detail to arrive at a configuration for the instrument and its major subsystems. Our approach throughout the configuration design was to take a systems perspective and trade requirements between subsystems, wherever possible, to arrive at configurations which made maximum use of existing, proven technology or relatively straightforward extensions to existing technology to reduce risk and cost. At the conclusion of Phase 1 we arrived at a configuration for LAWS which meets the performance requirements, yet which is less complex than previous designs of space-based wind sensors (e.g. Windsat), employs lightweight technologies to meet its weight goals (less than 800kg) and sufficiently flexible to offer various operational scenarios with power requirements from about 2 kW to 3 kW. The Phase 1 Final Report was released in March 1990. The 21-month Phase 2 began in October 1990. The requirement to accommodate LAWS as an attached payload on Space Station Freedom was deleted and the orbit altitude for the Japanese polar orbiting platform was changed from 824 km to 705 km. The power allocated to LAWS was reduced to 2.2 kW from 3 kW. Subsequently the availability of a Japanese Polar Orbiting Platform was called into question and LAWS accommodation studies were continued using a conceptual, ATLAS-launched platform supplied by MSFC. In March 1991 a modification to the original contracts was funded to provide a LAWS laser breadboard which could demonstrate all the performance requirements of the LAWS laser. Also funded as part of the same contract extension was a lifetest demonstration using an existing laser at STI. The breadboard extension was an eighteen month effort and the period of performance was therefore extended to September 30, 1992.

Source record↗

DOE OSTI2021

Large-Scale Welding Process Simulation by GPU Parallelized Computing

The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. Furthermore, the efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes for large-scale structures.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1999

Coherent Doppler Wind Lidar Technology for Space Based Wind Measurements Including SPARCLE

It has been over 30 years since coherent lidar systems first measured wind velocity, and over 20 years since the "ultimate application" of measuring Earth's winds from space was conceived. Coherent or heterodyne optical detection involves the combination (or mixing) of the returned optical field with a local oscillator (LO) laser's optical field on the optical detector. This detection technique yields the benefits of dramatically improved signal-to-noise ratios; insensitivity to detector noise, background light and multiply scattered light; reduction of the returned signal's dynamic range; and preservation of the optical signal spectrum for electronic and computer processing. (Note that lidar systems are also referred to as optical radar, laser radar, and LADAR systems.) Many individuals, agencies, and countries have pursued the goal of space-based wind measurements through technology development, experiments, field campaigns and studies.

Kavaya, Michael J.↗

DOE OSTI2020

Pre-Ionization Controlled Laser Plasma Formation for Ignition Applications (Final Scientific/Technical Report)

This report consists of three grand funded papers. Abstracts for each follow. 1) In this work, we present experimental and modeling studies of air pre-ionization using ultraviolet (UV) laser pulses and its effect on laser breakdown of an overlapped near-infrared (NIR) pulse. Experimental studies are conducted with a 266 nm beam (fourth harmonic of Nd:YAG) for UV pre-ionization and an overlapped 1064 nm NIR beam (fundamental of Nd:YAG), both having pulse duration of 10 ns. Results show that the UV beam produces a pre-ionized volume which assists in breakdown of the NIR beam, leading to reduction in NIR breakdown threshold by factor of >2. Numerical modeling is performed to examine the ionization and breakdown of both beams. The modeled breakdown threshold of the NIR, including assist by pre-ionization, is in reasonable agreement with the experimental results. 2) The present contribution compares the energy absorption, optical emission, temperature, and fluid dynamics of ultraviolet (UV) λ = 266 nm and near infrared (NIR) λ = 1064 nm nanosecond laser induced plasmas in ambient air. For UV pulses at the conditions studied, energy absorption by the plasmas increases relatively gradually with laser pulse energy starting at delivered energy of E~8 mJ. Corresponding measurements of plasma luminosity show that the absorption of UV radiation does not necessarily result in visible plasma emission. For the NIR induced plasmas, the energy absorption profile is far more abrupt and begins at ~55 mJ. In contrast with UV, the absorption of NIR radiation is always accompanied by intense optical emission. The temperatures of both types of plasma have been measured with Rayleigh scattering thermometry (at times after the Thomson signal sufficiently diminishes). The UV plasmas can attain a wider range of temperatures, including lower temperatures, depending on the pulse energy (e.g., T ~400–2000K for E ~7–35 mJ at Δt = 10 μs after the pulse) while the NIR plasmas show only hotter temperatures (e.g., T ~ 12 000 K for E = 75 mJ at Δt = 10 μs after the pulse) as is consistent with the literature. Differences in the fluid dynamics for UV versus NIR pulses are shown with Schlieren imaging. In this work, the contrast in the UV and NIR plasma threshold behavior is attributed to differing roles of avalanche ionization and multiphoton ionization as is also illustrated by a simple numerical model. 3) The present contribution examines the impact of plasma dynamics and plasma-driven fluid dynamics on the flame growth of laser ignited mixtures and shows that a new dual-pulse scheme can be used to control the kernel formation process in ways that extend the lean ignition limit. We perform a comparative study between (conventional) single-pulse laser ignition (λ = 1064 nm) and a novel dual-pulse method based on combining an ultraviolet (UV) pre-ionization pulse (λ = 266 nm) with an overlapped near-infrared (NIR) energy addition pulse (λ = 1064 nm). We employ OH* chemiluminescence to visualize the evolution of the early flame kernel. For single-pulse laser ignition at lean conditions, the flame kernel separates through third lobe detachment, corresponding to high strain rates that extinguish the flame. In this work, we investigate the capabilities of the dual-pulse to control the plasma-driven fluid dynamics by adjusting the axial offset of the two focal points. In particular, we find there exists a beam waist offset whereby the resulting vorticity suppresses formation of the third lobe, consequently reducing flame stretch. With this approach, we demonstrate that the dual-pulse method enables reduced flame speeds (at early times), an extended lean limit, increased combustion efficiency, and decreased laser energy requirements.

Mechanical engineering↗

NASA NTRS1975

Computer program compatible with a laser nephelometer

The laser nephelometer data system was updated to provide magnetic tape recording of data, and real time or near real time processing of data to provide particle size distribution and liquid water content. Digital circuits were provided to interface the laser nephelometer to a Data General Nova 1200 minicomputer. Communications are via a teletypewriter. A dual Linc Magnetic Tape System is used for program storage and data recording. Operational programs utilize the Data General Real-Time Operating System (RTOS) and the ERT AIRMAP Real-Time Operating System (ARTS). The programs provide for acquiring data from the laser nephelometer, acquiring data from auxiliary sources, keeping time, performing real time calculations, recording data and communicating with the teletypewriter.

Paroskie, R. M.↗

NASA NTRS2013

Per-Pixel, Dual-Counter Scheme for Optical Communications

Free space optical communications links from deep space are projected to fulfill future NASA communication requirements for 2020 and beyond. Accurate laser-beam pointing is required to achieve high data rates at low power levels.This innovation is a per-pixel processing scheme using a pair of three-state digital counters to implement acquisition and tracking of a dim laser beacon transmitted from Earth for pointing control of an interplanetary optical communications system using a focal plane array of single sensitive detectors. It shows how to implement dim beacon acquisition and tracking for an interplanetary optical transceiver with a method that is suitable for both achieving theoretical performance, as well as supporting additional functions of high data rate forward links and precision spacecraft ranging.

Farr, William H.↗

NASA NTRS1982

Containerless high temperature property measurements by atomic fluorescence

Laser induced fluorescence techniques were developed for the containerless study of high temperature processes, material properties, levitation, and heating techniques for containerless earth-based experimentation. Experiments were performed in which fluorescence of atomic aluminum, mercury, or tungsten were studied. These experiments include measurements of: (1) Al atom evaporation from CW CO2 laser heated and aerodynamically levitated sapphire and alumina spheres, and self-supported sapphire filaments, (2) Al atom reaction with ambient oxygen in the wake of a levitated specimen, (3) Hg atom concentrations in the wake of levitated alumina and sapphire spheres, relative to the ambient Hg atom concentration, (4) Hg atom concentrations in supersonic levitation jets, and (5) metastable, electronically excited W atom concentrations produced by evaporation of an electrically heated tungsten filament.

Nordine, P. C.↗