Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “laser processing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,711 records · Page 95

Structure–property relations of binary ferrite melts

Molten ferrite systems are used in the smelting and refining processes in steelmaking, to reduce the loss of metals in slags and to accelerate reaction rates. Here, high-energy x-ray diffraction experiments have been performed on aerodynamically levitated molten spheres of 43BaO–57FeO X and 43SrO–57FeO X at 1873 K using laser beam heating. The composition was varied within the range of x = 1–1.5 by changing the oxygen partial pressure of the levitation gas. The corresponding x-ray pair distribution functions have been interpreted using empirical potential structure refinement (EPSR) modeling. In oxygen-rich melts (x = 1.5), our EPSR models indicate very similar structures for the different alkaline-earth liquids, with both the Ba–O and Sr–O coordination numbers to be ∼8.4 and the total Fe–O coordination numbers ∼5.7. However, our models show that in reducing environments, the Fe 3+ and Fe 2+ ions exhibit very different behaviors in the Ba- and Sr-ferrite liquids. In the Ba-ferrite melt, the Fe 3+ –O coordination number decreases from 5.7 (at x = 1.5) to 5.2 (at x = 1.07), whereas Fe 2+ –O remains constant at ∼5.0 across the same compositional range. In the Sr melts, both the Fe 2+ –O and Fe 3+ –O coordination numbers rise from ∼5.7 (at x = 1.5) to 6.3 (at x = 1.07). All models show the structures to be heterogeneous with intertwined nanometer sized clusters or channels of Ba/Sr–O and Fe–O polyhedra that grow as oxygen content is reduced. Changes in the viscosity and electrical properties are interpreted in terms of the number of bridging and non-bridging oxygens associated with FeO 4 tetrahedra and concentration of charge carriers, respectively.

Benmore, Chris J. [Argonne National Laboratory (AN↗

Experimental Characterization of Photoemission from Plasmonic Nanogroove Arrays

Metal photocathodes are an important source of high-brightness electron beams, ubiquitous in the operation of both large-scale accelerators and table-top microscopes. When the surface of a metal is nanoengineered with patterns on the order of the optical wavelength, it can lead to the excitation and confinement of surface-plasmon-polariton waves that drive nonlinear photoemission. In this work, we aim to evaluate gold plasmonic nanogrooves as a concept for producing bright electron beams for accelerators via nonlinear photoemission. Here, we do this by first comparing their optical properties to numerical calculations from first principles to confirm our ability to fabricate these nanoscale structures. Their nonlinear photoemission yield is found by measuring emitted photocurrent as the intensity of their driving laser is varied. Finally, the mean transverse energy of this electron source is found using the solenoid-scan technique. Our data demonstrate the ability of these cathodes to provide a tenfold enhancement in the efficiency of photoemission over flat metals driven with a linear process. We find that these cathodes are robust and capable of reaching sustained average currents over 100 nA at optical intensities larger than 2 GW cm –2 with no degradation of performance. The emittance of the generated beam is found to be highly asymmetric, a fact we can explain with calculations involving the also asymmetric roughness of the patterned surface. These results demonstrate the use of nanoengineered surfaces as enhanced photocathodes, providing a robust air-stable source of high-average-current electron beams hopefully with great potential for industrial and scientific applications.

47 OTHER INSTRUMENTATION↗

Expansion-Driven Self-Magnetization of High-Energy-Density Plasmas

Understanding plasma self-magnetization is one of the fundamental challenges in both laboratory and astrophysical plasmas. Self-magnetization can modify plasma transport properties, altering the dynamical evolution of plasmas. Multiple high-energy-density (HED) experiments have observed the formation of ion-scale magnetic filaments of megagauss strength, though their origin remains debated. Here, in this study, we conduct 2D collisional particle-in-cell (PIC) simulations with a laser ray-tracing module for a fully self-consistent simulation of the plasma ablation, expansion, and magnetization. The simulations use a planar geometry, effectively suppressing the Biermann magnetic fields, to focus on anisotropy-driven instabilities. The laser intensity is varied between 10 13 and 10 14 W/cm 2 , which is relevant to HED and inertial fusion experiments where collisions must be considered. We find that, above a critical intensity, the plasma rapidly self-magnetizes via an expansion-driven Weibel process, producing a plasma beta of 100 (𝛽 = 8⁢𝜋⁢𝑘 𝐵 ⁢𝑛 𝑒 ⁢𝑇 𝑒 /𝐵 2 ) and Hall parameter 𝜔 ce ⁢𝜏 𝑒 >1 within the first few hundred picoseconds. The magnetic field is sufficiently strong to modify plasma heat transport, and simulations with an artificially suppressed magnetic field show noticeably different temperature profiles.

Lezhnin, K. V. [Princeton Plasma Physics Laborator↗

Photoemission Induced Plasma Breakdown (Update)

Laser-induced photoemission of electrons offers opportunities to trigger and control plasmas and discharges. However, the underlying mechanisms are not sufficiently characterized to be fully utilized. Photoemission is highly nonlinear, achieved through multiphoton absorption, above threshold ionization, photo-assisted tunneling, etc., where the dominant process depends on the work function of the material, photon energy and associated fields, surface heating, background fields, etc. To characterize the effects of photoemission on breakdown, breakdown experiments were performed and interpreted using a 0D plasma discharge circuit model and quantum model of photoemission.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Specification of EBR-II Fabricated Fuel Diameter Data

All IFR EBR-II fuel pins were fabricated at one of the related fuel fabrication facilities at Argonne National Laboratory-West, at the EBR-II site [1]. U-Pu-Zr experimental pins were fabricated at the Experimental Fuels Laboratory (EFL), which was established in April of 1984 after the positive acceptance of the IFR concept, while the U-Zr experimental pins were fabricated at the Fuel Manufacturing Facility (FMF), along with the driver fuel pins [2]. The injection-casting fabrication process is described in detail in ref [1]. All the fuel pins that were loaded into EBR-II were examined after fabrication to ensure that they met the design dimensional requirements and tolerances prior to assembly. Fuel slug diameter was measured with either a laser profilometer (at FMF) or a hand micrometer (at EFL), at a minimum of 1-inch intervals over the length of the fuel slug, as shown in Figure 1 [2]. In all cases the average fuel diameter is reported, in some cases with additional summary statistics (e.g., minimum, maximum), and in rare cases the complete record of axially-varying fuel diameters is available. It should be noted that in cases where axial varying data is available, in general the orientation of the slug was not recorded or carried over to loading of the pin, so a diameter measurement at the bottom of the fabricated slug does not necessarily correspond to the bottom of the loaded slug, as it may have been loaded in either orientation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Cooling dynamics of two titanium alloys during laser powder bed fusion probed with in situ X-ray imaging and diffraction

Metal parts produced by laser powder bed fusion (LPBF) additive manufacturing exhibit characteristic microstructures comparable to those observed in laser welding. The primary cause of this characteristic microstructure is rapid, localized heating and cooling cycles, which result in extreme thermal gradients where material solidification is followed by fast cooling in the solid state. The final microstructure and mechanical performance are also influenced by pore formation caused by melt pool fluid dynamics. Here, we use high speed, in situ X-ray diffraction to probe the kinetics of cooling and solid-solid phase transitions after laser melting in two aerospace titanium alloys: Ti-6Al-4V, an α + β alloy; and Ti-5Al-5V-5Mo-3Cr, a near-β alloy. We complement these diffraction studies with in situ X-ray imaging to probe melt pool dynamics and pore formation. From these two complementary probes, we quantify pore formation during melting and the subsequent microstructural evolution as the material rapidly cools after solidification. These results are critical for understanding defect formation and residual stress development in different titanium alloys under LPBF conditions and can help inform process models to predict final part performance.

36 MATERIALS SCIENCE↗

Adhesion Testing of Direct-Write Printed Ink on Metallic Structural Components

The successful adoption of additive manufacturing for the rapid prototyping of direct-write printed electronics requires the establishment of quantifiable metrics that can interrogate device performance. One measure of performance is the adhesion strength between the substrate and printed film interface, which is critical since the strength of this interface can dictate the accuracy and reliability of the printed device. In this work, a non-contact laser-induced spallation technique was used to quantify the adhesion of silver printed films on aluminum alloy substrates. The laser-based method was compared to a standardized pull-off adhesion test, which provided baseline measurements of adhesion strength. The sintering conditions were shown to play an important role in the film-substrate adhesion strength, as well as the cohesion and ductility of the film itself. The methods and results described in this work support the establishment of process control steps that are necessary for quickly verifying the reliability of printed devices prior to their deployment in critical experiments.

Adhesion test↗

Island scanning pattern optimization for residual deformation mitigation in laser powder bed fusion via sequential inherent strain method and sensitivity analysis

Laser powder bed fusion (L-PBF) has emerged as one of the mainstream additive manufacturing approaches for fabricating metal parts with complex geometries and intricate internal structures. However, large deformation associated with rapid heating and cooling can lead to build failure and requires post-processing which may increase manufacturing cost and prolong the production period. Here in this work, an island scanning pattern design method is proposed to optimize the scanning direction of each island in order to reduce part deformation after cutting off the build platform. The objective of this optimization is to minimize the upward bending of the part after sectioning, which allows the part deformation to satisfy the tolerance requirement or reduce the post heat treatment time. Inherent strain method is employed in the sequential finite element analysis consisting of layer-by-layer activations and sectioning for fast residual distortion prediction. Full sequential sensitivity analysis for the formulated optimization is provided to update the island scanning directions. To show the feasibility and effectiveness of the proposed method, the scanning patterns of a block structure and a connecting rod were designed and parts were fabricated using an open architecture L-PBF machine. The fabrication experiments demonstrated that the residual deformation of both parts fabricated by optimized scanning pattern can be reduced by over 50% compared to the initial scanning patterns, which demonstrate the effectiveness of the proposed method.

36 MATERIALS SCIENCE↗

Ultra-high temperature testing and performance of L-PBF C103

Additive Manufacturing (AM) of refractory alloys is gaining traction as a materials processing route for components subject to extreme temperature environments. Due to the low oxidation resistance of refractory alloys, novel methods for evaluating their elevated temperature performance must be developed. In this work, a Gleeble® 3800 thermomechanical load frame was modified to evaluate the mechanical properties of laser powder bed fusion (L-PBF) consolidated niobium alloy C103 ranging from room temperature (RT) to 1400 °C. The fixturing and sample geometry were designed to accommodate Joule heating and prevent damage to the test chamber. Oxidation of the samples was minimized via testing in vacuum level of 1E-5 Torr. Ultimate tensile strength (UTS), yield strength (YS), elongation, and strain-hardening behavior were determined as a function of temperature. L-PBF C103 presented an average UTS of ∼650 MPa and over 25 % elongation at RT. Above RT, the UTS and YS dropped then leveled off from 500 °C to 1000 °C with values ranging from ∼400 MPa to ∼460 MPa, which is consistent with dynamic strain aging observed in this class of alloys. The strength rapidly declined after 1200 °C to ∼150 MPa at 1400 °C. Fractography indicated ductile fractures for the C103 at all test temperatures, and Electron Backscatter Diffraction (EBSD) analysis revealed a textured microstructure and the presence of dynamic recrystallization within the necked region of the sample tested at 1400 °C.

33 ADVANCED PROPULSION SYSTEMS↗

Additive manufacturing of silicon carbide for nuclear applications

Additive manufacturing (AM) is a rapidly evolving technology being considered for nuclear applications. A special focus on AM to fabricate nuclear-grade silicon carbide (SiC) is explored in this paper. First, we present currently available AM processing options for SiC. AM methods commonly used for other ceramics, in which the feedstocks are forms of polymers, powders, and/or reactive chemical vapors, are also applicable to SiC. SiC phases are formed by pyrolysis of pre-ceramic polymer, direct reaction of powder precursors, sintering of SiC powders, or chemical vapor deposition/infiltration. Second, we discuss how the different microstructures of SiC materials fabricated by various processing methods affect their behavior in nuclear environments. Third, we discuss state-of-the-art AM technologies for the fabrication of relatively pure SiC, which show great potential to retain its strength under neutron irradiation: (1) binder jet printing followed by chemical vapor infiltration, (2) laser chemical vapor deposition, and (3) selective laser sintering of SiC powders.

36 MATERIALS SCIENCE↗

Martensite decomposition during rapid heating of Ti-6Al-4V studied via in situ synchrotron X-ray diffraction

Martensite, α‘, commonly appears in Ti-6Al-4V upon rapid cooling from above the β-transus temperature. It is known that α‘ decomposes into α and β at high temperatures but well below the β-transus temperature. Here, we study the decomposition of martensitic Ti-6Al-4V under rapid laser heating, employing in situ synchrotron X-ray diffraction. A comparison is made with post-annealed Ti-6Al-4V under heating to elucidate changes without martensite decomposition. The fast acquisition of X-ray diffraction data at 250 Hz temporally resolves the decomposition process initiated by annihilating dislocations in α‘. The recovery process is accompanied by structural changes in martensite, followed by the phase transformation to β. Thermal profiles estimated from the lattice parameter data reveal the influence of heating rates and dislocation densities on the decomposition process. Throughout the analysis of the diffraction profiles with respect to estimated temperature, we propose a straightforward method for approximating the initiation temperature of martensite decomposition.

42 ENGINEERING↗

Phenomenological mechanisms of hybrid organic–inorganic perovskite thin film deposition by RIR-MAPLE

Resonant infrared, matrix-assisted pulsed laser evaporation (RIR-MAPLE) is a promising technique for the physical vapor deposition of hybrid organic–inorganic perovskites. The approach already has been used to deposit both three-dimensional and two-dimensional hybrid perovskites with material quality comparable to those synthesized by solution processing. However, the phenomenological mechanisms of hybrid perovskite film formation by RIR-MAPLE have not been articulated. Therefore, this work presents a careful investigation of film formation mechanisms of three-dimensional methylammonium lead halide perovskites by considering the temporal evolution of morphology, crystallinity, and optical properties of films deposited by RIR-MAPLE.

Barraza, E. T. (ORCID:0000000328681496)↗

Photothermal alternative to device fabrication using atomic precision advanced manufacturing techniques

The attachment of dopant precursor molecules to depassivated areas of hydrogen-terminated silicon templated with a scanning tunneling microscope (STM) has been used to create electronic devices with sub-nanometer precision, typically for quantum physics demonstrations, and to dope silicon past the solid-solubility limit, with potential applications in microelectronics and plasmonics. However, this process, which we call atomic precision advanced manufacturing (APAM), currently lacks the throughput required to develop sophisticated applications because there is no proven scalable hydrogen lithography pathway. Here, we demonstrate and characterize an APAM device workflow where STM lithography has been replaced with photolithography. An ultraviolet laser is shown to locally heat silicon controllably above the temperature required for hydrogen depassivation. STM images indicate a narrow range of laser energy density where hydrogen has been depassivated, and the surface remains well-ordered. A model for photothermal heating of silicon predicts a local temperature which is consistent with atomic-scale STM images of the photo-patterned regions. Finally, a simple device made by exposing photo-depassivated silicon to phosphine is found to have a carrier density and mobility similar to that produced by similar devices patterned by STM.

42 ENGINEERING↗

Strong-field QED experiments using the BELLA PW laser dual beamlines

The petawatt (PW) laser facility of the Berkeley Lab Laser Accelerator (BELLA) Center has recently commissioned its second laser pulse transport line. This new beamline can be operated in parallel with the first beamline and enables strong-field quantum electrodynamics (SF-QED) experiments at BELLA. In this paper, we present an overview of the upgraded BELLA PW facility with a SF-QED experimental layout in which intense laser pulses collide with GeV-class laser-wakefield-accelerated electron beams. We present simulation results showing that experiments will allow the study of laser-particle interactions from the classical to the SF-QED regime with a nonlinear quantum parameter of up to χ ~2. Additionally, we show that experiments will enable the study and production of GeV-class, mrad-divergence positron beams via the Breit–Wheeler process. Graphical abstract: [Figure not available: see fulltext.].

43 PARTICLE ACCELERATORS↗

Generative Physics-Informed Neural Network Solving Multi-Scale and Multi-Phase Plasma Chemical Flow Field

Low-temperature plasmas (LTPs) are non-equilibrium systems with near-room-temperature gas and highly energetic electrons. This makes them ideal for delicate applications in biomedicine and semiconductor manufacturing, enabling processes like wound healing, sterilization, etching, and plasma-enhanced chemical vapor deposition without thermal damage. However, LTPs involve complex chemistries, with hundreds of species and thousands of reactions, complicating their diagnosis, prediction, and control. Conventional diagnostics, such as Fourier-transform infrared spectroscopy (FTIR), laser-induced fluorescence (LIF), and optical emission spectroscopy (OES), offer limited species detection, while mass spectrometry (MS) struggles with low-sensitivity species. Additionally, LTP simulations face multi-scale challenges, as macroscopic fluid dynamics and microscopic particle collisions operate on vastly different timescales. To address these issues, we developed an artificial intelligence (AI) based diagnostic system: a generative physics-informed neural network (PINN-Gen) that can predict spatially resolved species concentrations and temperatures in LTPs by integrating experimental data from planar LIF with microscopic plasma chemical kinetics and macroscopic fluid mechanics, including plasma-liquid interactions at the interface between two phases. PINN-Gen solves no equations but checks the errors of physical laws by substituting the output from neural network, and the comparison with the experimental results. Thus, it naturally avoids the multi-scale difficulty of numerical simulations and predicts the results of conventionally unsolvable multi-scale and multi-phase problems. The real-time prediction will be robust due to the physical information used in the training of such a neural network, and only very limited input of condition required due to its generative feature.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Semi-empirical quantum optics for mid-infrared molecular nanophotonics

Nanoscale infrared (IR) resonators with sub-diffraction limited mode volumes and open geometries have emerged as new platforms for implementing cavity quantum electrodynamics at room temperature. The use of IR nanoantennas and tip nanoprobes to study strong light–matter coupling of molecular vibrations with the vacuum field can be exploited for IR quantum control with nanometer spatial and femtosecond temporal resolution. In order to advance the development of molecule-based quantum nanophotonics in the mid-IR, we propose a generally applicable semi-empirical methodology based on quantum optics to describe light–matter interaction in systems driven by mid-IR femtosecond laser pulses. The theory is shown to reproduce recent experiments on the acceleration of the vibrational relaxation rate in infrared nanostructures. It also provides physical insights on the implementation of coherent phase rotations of the near-field using broadband nanotips. We then apply the quantum framework to develop general tip-design rules for the experimental manipulation of vibrational strong coupling and Fano interference effects in open infrared resonators. We finally propose the possibility of transferring the natural anharmonicity of molecular vibrational levels to the resonator near-field in the weak coupling regime to implement intensity-dependent phase shifts of the coupled system response with strong pulses and develop a vibrational chirping model to understand the effect. The semi-empirical quantum theory is equivalent to first-principles techniques based on Maxwell’s equations, but its lower computational cost suggests its use as a rapid design tool for the development of strongly coupled infrared nanophotonic hardware for applications ranging from quantum control of materials to quantum information processing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Ultrafast Laser Pulse Generation by Mode Locking: MATLAB-Based Demonstrations

Ultrafast laser spectroscopy is a valuable and increasingly accessible technique for studies of rapid chemical reactions. Critical to ultrafast spectroscopy is the concept of mode locking, a technique that enables a fixed phase relationship between laser modes, resulting in laser pulses with very short duration (in the fs or ps range). Despite the increasing importance of ultrafast lasers in chemistry, the introduction of key concepts behind their operation into the undergraduate and graduate chemistry coursework has been limited. To help the incorporation of these topics into chemistry courses, we report here a hands-on activity that helps students develop an intuitive understanding of the factors that impact electromagnetic wave evolution in optical cavities and the process of mode locking. We first provide the theoretical background by introducing cavity modes and contrasting them with well-known propagating electromagnetic waves. We then explore what happens when modes are added and how the relative phase between the modes affects their behavior. In the second section of this report, three teaching modules are provided, along with associated MATLAB codes and animated images, that can be used in the classroom to introduce concepts of cavity modes and mode locking. These teaching modules start by contrasting propagating electromagnetic waves with cavity modes and then illustrate what happens when multiple modes are present in the cavity and how the relative phase between the modes affects the overall electromagnetic field in the cavity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Characterization of single-shot attosecond pulses with angular streaking photoelectron spectra

Most of the traditional attosecond pulse retrieval algorithms are based on a so-called attosecond streak camera technique, in which the momentum of the electron is shifted by an amount depending on the relative time delay between the attosecond pulse and the streaking infrared pulse. Thus, temporal information of the attosecond pulse is encoded in the amount of momentum shift in the streaked photoelectron momentum spectrogram S(p,τ), where p is the momentum of the electron along the polarization direction and τ is the time delay. An iterative algorithm is then employed to reconstruct the attosecond pulse from the streaking spectrogram. This method, however, cannot be applied to attosecond pulses generated from free-electron x-ray lasers where each single shot is different and stochastic in time. However, using a circularly polarized infrared laser as the streaking field, a two (or three)-dimensional angular streaking electron spectrum can be used to retrieve attosecond pulses for each shot, as well as the time delay with respect to the circularly polarized IR field. Here we show that a retrieval algorithm previously developed for the traditional streaking spectrogram can be modified to efficiently characterize single-shot attosecond pulses. The methods have been applied to retrieve 188 single shots from recent experiments. We analyze the statistical behavior of these 188 pulses in terms of pulse duration, bandwidth, pulse peak energy, and time delay with respect to the IR field. Furthermore, the retrieval algorithm is efficient and can be easily used to characterize a large number of shots in future experiments for attosecond pulses at free-electron x-ray laser facilities.

74 ATOMIC AND MOLECULAR PHYSICS↗