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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 1,783 records · Page 99
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Laboratory Study of Nonlinear QED in Intense Laser-Matter Interactions

The goal of the project was to investigate the interaction of powerful laser light with matter, which is of fundamental interest to electrodynamics, thermonuclear fusion plasmas, and high-energy-density physics for DOE. Experiments on highly nonlinear relativistic interactions were performed using the state-of-the-art DIOCLES laser at the Extreme Light Laboratory of the University of Nebraska–Lincoln (UNL). We have demonstrated a novel testbed for laser-plasma interactions in which laser pulses collided in plasma with femtosecond and micron-scale accuracy under extreme experiment conditions. This capability is crucial for future radiation reaction experiments and nonlinear QED studies. Moreover, this is also a milestone towards the efficient generation of GeV electron beams via travelling wave laser wakefield accelerator. We proposed a novel idea for measuring the radiation reaction process using travelling wave Thomson scattering, which was studied in numerical simulations. This method allows unambiguous measurement of radiation reaction in a single shot, therefore, surpassing the conventional methods, which suffer severely from the shot-to-shot fluctuations, due to the instability of laser wavefield acceleration.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2019

Single-Shot Multi-keV X-Ray Absorption Spectroscopy Using an Ultrashort Laser-Wakefield Accelerator Source

We report that single-shot absorption measurements have been performed using the multi-keV x rays generated by a laser-wakefield accelerator. A 200 TW laser was used to drive a laser-wakefield accelerator in a mode which produced broadband electron beams with a maximum energy above 1 GeVand a broad divergence of ≈15 mrad FWHM. Betatron oscillations of these electrons generated 1.2 ± 0.2 x 10 6 photons/eV in the 5 keV region, with a signal-to-noise ratio of approximately 300:1. This was sufficient to allow high-resolution x-ray absorption near-edge structure measurements at the K edge of a titanium sample in a single shot. We demonstrate that this source is capable of single-shot, simultaneous measurements of both the electron and ion distributions in matter heated to eV temperatures by comparison with density functional theory simulations. The unique combination of a high-flux, large bandwidth, few femtosecond duration x-ray pulse synchronized to a high-power laser will enable key advances in the study of ultrafast energetic processes such as electron-ion equilibration.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2019

GRCop-42 Development and Hot-fire Testing Using Additive Manufacturing Powder Bed Fusion for Channel-Cooled Combustion Chambers

GRCop-42 is a high conductivity, high-strength dispersion strengthened copper-alloy for use in high heat flux applications such as liquid rocket engine combustion devices. This alloy is part of the family of NASA-developed GRCop, copper-chrome-niobium alloys. GRCop alloys were developed for harsh environments specific to regeneratively-cooled combustion chambers and nozzles with good oxidation resistance. Significant development was completed on the GRCop-84 and GRCop-42 alloys in the extruded wrought form demonstrating feasibility for combustion chambers. NASA has recently developed a process for additive manufacturing, specifically Powder Bed Fusion (PBF) or Selective Laser Melting (SLM), of GRCop-42 to establish parameters, characterize the material, and complete testing of components with complex internal features. This evolution of the GRCop-42 was based on the successful predecessor development work using GRCop-84 with the motivation of establishing a new copper-alloy option for use in NASA, government, and industry programs with SLM. A few advantages have been shown with the GRCop-42 that include higher conductivity and faster build speeds over the GRCop-84, and a simplified powder supply chain. Initial property development has shown that it is possible to produce high density builds with strengths equivalent to wrought GRCop-42 and a conductivity greater than GRCop-84. The GRCop-42 has completed process development and initial properties have been established. Several demonstrator combustion chambers have also been fabricated with the SLM GRCop-42 that include integral channels and closeouts. Additional test units have been fabricated and are completing substantial hot-fire testing to demonstrate performance of the material, process, and design.

Gradl, Paul R.↗
NASA NTRS1988

Optical communication with semiconductor laser diodes

Slot timing recovery in a direct detection optical PPM communication system can be achieved by processing the photodetector waveform with a nonlinear device whose output forms the input to a phase lock group. The choice of a simple transition detector as the nonlinearity is shown to give satisfactory synchronization performance. The rms phase error of the recovered slot clock and the effect of slot timing jitter on the bit error probability were directly measured. The experimental system consisted of an AlGaAs laser diode (lambda = 834 nm) and a silicon avalanche photodiode (APD) photodetector and used Q=4 PPM signaling operated at a source data rate of 25 megabits/second. The mathematical model developed to characterize system performance is shown to be in good agreement with actual performance measurements. The use of the recovered slot clock in the receiver resulted in no degradation in receiver sensitivity compared to a system with perfect slot timing. The system achieved a bit error probability of 10 to the minus 6 power at received signal energies corresponding to an average of less than 60 detected photons per information bit.

Davidson, F.↗
NASA NTRS2019

Manufacturing of Thermoset Polyimide Composites by Laser Sintering

Selective Laser Sintering (SLS) is an additive manufacturing technique that builds 3D models layer by layer using a laser to selectively melt cross sections in powdered polymeric materials, following sequential slices of the computer-aided design (CAD) model. SLS generally uses thermoplastic polymeric powders such as polyamides. The resultant 3D-printed objects are often weaker in their strength compared to traditionally processed materials, due to their higher porosity. This paper described the process development of using melt-processable imide oligomers terminated with reactive 4-phenylethynylphthalic anhydride (4-PEPA) to conduct laser sintering (LS). The first successful 3D-printing of high temperature RTM370 thermoset polyimide carbon fiber composites were further post-cured to promote additional crosslinking for achieving higher temperature (T g = 370°C) capability. Another novel imide oligomer, RTM385-SLS, formulated with a complex melt viscosity [ƞ*] of ~104-105 poise is also suitable for LS. RTM385-SLS resin powder was mixed with 20-25% of hexagonal boron nitride (h-BN) and subjected to LS to print out “Green” specimens which could be further post-cured to afford a thermally conductive but electrically insulating composites with high T g of 385 °C. The cured composite specimens were then subjected to mechanical testing, thermal conductivity and porosity measurements as well as SEM characterization.

additive Manufacturing↗
NASA NTRS1980

Modeling of growth, evaporation and sedimentation effects on transmission of visible and IR laser beams in artificial fogs

The dense polydisperse aerosol particles in a quiet chamber may spontaneously go through different microphysical processes including gravitational sedimentation, thermal coagulation, and growth or evaporation. In an earlier paper, we presented the results of a parametric study of the combined and separate effects of thermal coagulation and sedimentation on the time dependence of extinction of four visible and IR laser beams traversing an aerosol medium. As a continuation of this series of studies, the separate and combined effects of growth or evaporation and gravitational sedimentation on the time dependence of extinction of the same four visible and IR laser beams traversing in artificial fogs will be reported in this paper. The method of numerically modeling the change of water droplet size distribution with time due to growth/evaporation and the cutoff of larger aerosols due to gravitational sedimentation is described in detail. Factors governing the relative importance of these two processes are discussed. Results of this study show that the relative humidity or ambient temperature is a crucial parameter in determining the optical depth of the water droplet and aerosol media undergoing microphysical processes.

Yue, G. K.↗
DOE OSTI2025

Multi-physics Topology OPtimization and Additive Manufacturing for High-temperature Heat Exchangers

This research significantly advances the understanding of high-temperature heat exchanger design through an integrated approach that combines topology optimization (TO), triply periodic minimal surface (TPMS) structures, additive manufacturing (AM) and thermohydraulic testing. Each of these components contributes uniquely to a unified, high-performance design, fabrication and testing workflow. Topology optimization serves as the foundation of the design methodology by providing a systematic way to determine the most effective material layout for separating hot and cold fluids while maximizing thermal performance. The researchers introduced a novel three-material optimization framework using two density fields to represent hot fluid, cold fluid, and solid domains. This approach enables automated discovery of optimal shapes and flow paths that cannot be intuitively designed, especially under constraints imposed by manufacturing technologies. Furthermore, constraints such as minimal wall thickness and overhang angles were embedded into the optimization process, ensuring that resulting designs are not only thermally efficient but also manufacturable using modern additive techniques. In parallel, the study delves into the use of Gyroid-based TPMS geometries for constructing the core of the heat exchanger. TPMS structures are known for their high surface area, excellent fluid mixing capabilities, and minimal pressure drop characteristics. The researchers applied a data-driven modeling framework using Heteroscedastic Sparse Gaussian Process Regression (HSGPR) combined with genetic algorithms. This allowed for the rapid evaluation and optimization of key geometric parameters such as frequency, iso-value, and phase shift. The result was a set of Gyroid structures tailored for high heat transfer and low flow resistance, demonstrating clear improvements over conventional straight-channel designs. After the designing process, additive manufacturing played a critical role by turning these highly complex, optimized geometries into physical components. Utilizing Laser Powder Bed Fusion (LPBF) with Haynes 282, the study demonstrated the feasibility of fabricating these heat exchangers at high precision. Post-processing methods, including dilation-erosion operations, were applied to ensure local features adhered to self-supporting constraints. The fabricated structures were then subjected to thermohydraulic testing under conditions representative of supercritical CO 2 Brayton cycles, validating the predicted performance and confirming the viability of the full design-to-fabrication pipeline. Finally, thermohydraulic testing across the above studies served as a crucial experimental validation of advanced heat exchanger. Under consistent high-temperature and high-pressure conditions using supercritical CO 2 , the testing demonstrated that both TO and Gyroid-based TPMS designs significantly outperformed conventional straight-channel HXs. The TO design achieved a 115% increase in UA and NTU and a 27.6% boost in gravimetric power density, while the data-driven optimized Gyroid design delivered a 166% increase in UA and NTU and improved effectiveness from 68.7% to 86.1%. These results validate the simulation models, confirm the manufacturability of complex geometries under AM constraints, and provide key insights into design-performance trade-offs, thereby advancing the development of high-efficiency, compact heat exchangers for extreme environments.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Considerations of metal joining processes for space fabrication, construction and repair

A comprehensive evaluation is conducted of candidate processes for metalworking in orbital (vacuum-microgravity) conditions. Attention is given to electron-beam welding, brazing, gas-tungsten arc welding, laser welding, plasma arc welding, and gas-metal arc welding. It is established that several of these processes will be required to cover all foreseeable requirements. Microgravity effects are considered minor, and efforts are being concentrated on problems associated with vacuum conditions and with process-operator safety.

Russell, C.↗
DOE OSTI2022

Laser melting modes in metal powder bed fusion additive manufacturing

In laser powder bed fusion additive manufacturing of metals, extreme thermal conditions create many highly dynamic physical phenomena such as vaporization and recoil, Marangoni convection, and protrusion and keyhole instability. Collectively however, the full set of phenomena is too complicated for practical applications and, in reality, the melting modes are used as a guideline for printing. With increasing local material temperature beyond the boiling point, the mode can change from conduction to keyhole. These mode designations ignore laser-matter interaction details but in many cases are adequate to determine the approximate microstructures and hence the properties of the build. To date, no consistent, common, and coherent definitions have been agreed upon because of historic limitations in melt pool and vapor depression morphology measurements. Here, we distinguish process-based definitions of different melting modes from those based on postmortem evidence. The latter are mainly derived from the transverse cross-sections of the fusion zone, whereas the former come directly from time-resolved x-ray imaging of melt pool and vapor depression morphologies. These process-based definitions are more strict and physically sound, and they offer new guidelines for laser additive manufacturing practices and create new research directions. Further, we highlight the significance of the keyhole, which substantially enhances the laser energy absorption by the melt pool. Recent studies strongly suggest that stable-keyhole laser melting enables efficient, sustainable, and robust additive manufacturing. The realization of this scenario demands the development of multiphysics models, signal translations from morphology to other feasible signals, and in-process metrology across platforms and scales.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Rapid Identification of Synthetic Routes to Functional Metastable Phases Using X-ray Probed Laser Anneal Mapping (XPLAM) Time-Temperature Quench Maps

Many material systems have known or predicted functional phases that are metastable at standard temperature and pressure. While substantial advances have been made in the high-throughput and combinatorial synthesis of materials with a range of stoichiometries, investigation of thermal processing remains largely the domain of iterative uniform anneals or static gradients. Here we develop X-ray probed laser anneal mapping (XPLAM), a high throughput technique coupling spatially resolved X-ray diffraction with microsecond to millisecond laser gradient anneals to produce temperature–dwell–transformation (TDT) diagrams of the phase as a function of quench time and temperature. In addition to showing regimes where specific metastable phases form preferentially, TDT diagrams provide insight into the submillisecond kinetics of solid–solid phase transitions. This is a unique tool for mapping reaction pathways for metastable phases. As a first demonstration of XPLAM, we study Bi2O3, which has a rich set of polytypes, including the d-phase with an exceptionally high oxygen ion conductivity. We demonstrate the first annealing-driven synthesis of room temperature d-Bi2O3. We expect XPLAM to prove a powerful technique for rapid identification of synthetic routes to metastable phases and to generate the exhaustive data sets required for machine learning-guided exploration of materials processing.

36 MATERIALS SCIENCE↗
NASA NTRS2003

ICESat Laser Altimeter Pointing, Ranging and Timing Calibration from Integrated Residual Analysis: A Summary of Early Mission Results

On January 12, 2003 the Ice, Cloud and land Elevation Satellite (ICESat) was successfully placed into orbit. The ICESat mission carries the Geoscience Laser Altimeter System (GLAS), which consists of three near-infrared lasers that operate at 40 short pulses per second. The instrument has collected precise elevation measurements of the ice sheets, sea ice roughness and thickness, ocean and land surface elevations and surface reflectivity. The accurate geolocation of GLAS's surface returns, the spots from which the laser energy reflects on the Earth's surface, is a critical issue in the scientific application of these data Pointing, ranging, timing and orbit errors must be compensated to accurately geolocate the laser altimeter surface returns. Towards this end, the laser range observations can be fully exploited in an integrated residual analysis to accurately calibrate these geolocation/instrument parameters. Early mission ICESat data have been simultaneously processed as direct altimetry from ocean sweeps along with dynamic crossovers resulting in a preliminary calibration of laser pointing, ranging and timing. The calibration methodology and early mission analysis results are summarized in this paper along with future calibration activities.

Scott B Luthcke↗
NASA NTRS2000

Vertical Roughness of the Polar Regions of Mars from Mars Orbiter Laser Altimeter Pulse-Width Measurements

The sub-kilometer scale vertical roughness of the martian surface in the polar regions can be investigated using calibrated, optical pulse width data provided by the Mars Orbiter Laser Altimeter (MOLA). Garvin and others have previously discussed initial observations of what we have called "total vertical roughness" or TVR, as derived from MOLA optical pulse width observations acquired during the pre-mapping phases of the Mars Global Surveyor (MGS) mission. Here we present the first assessment of the Mars polar region properties of the TVR parameter from more than nine months of continuous mapping by MOLA as part of the MGS mapping mission. Other than meter-scale surface properties directly inferred from Mars Orbiter Camera (MOC) images, MOLA measurements of footprint-scale TVR represent the only direct measurements of the local vertical structure of the martian surface at approx. 150 m length scales. These types of data have previously been shown to correlate with geologic process histories for terrestrial desert surfaces on the basis of Shuttle Laser Altimeter (SLA) observations. Additional information is obtained in the original extended abstract.

Garvin, J. B.↗
NASA NTRS1985

Laser radar observation of the polar stratospheric aerosol layer

The polar stratosphere has been speculated to be an active sink region of various stratospheric materials; ozone, water vapor, NOX, aerosol particles and so on, but this process is not theoretically and/or observationally made clear. The observation of the polar stratospheric aerosol layer using laser radar certainly contributes to the study of the global transport of these stratospheric minor constituents. In addition to this, from the viewpoint of aerosol science, there may be many interesting phenomena which cannot be found in the stratosphere at mid and low latitudes; the effect of precipitation of high energy molecules and atoms, of very cold winter stratosphere, of very cold mesopause in summer. Laser radar observation is one of the main activities of the Antarctic Middle Atmosphere (AMA) project at Syowa Station (69.00 deg S, 39.35 deg E), Antarctica since May 1983. Laser radar measurement at Syowa Station is discussed in detail.

Iwasaka, Y.↗
DOE OSTI2021

Combining In-situ Diagnostics and Data Analytics for Discovery of Process-Structure-Property Relationships in AM parts – A Step Toward Digital Twins

In-situ additive manufacturing (AM) diagnostic tools (e.g., optical/infrared imaging, acoustic, etc.) already exist to correlate process anomalies to printed part defects. This current work aimed to augment existing capabilities by: 1) Incorporating in-situ imaging w/ machine learning (ML) image processing software (ORNL- developed "Peregrine") for AM process anomaly detection 2) Synchronizing multiple in-situ sensors for simultaneous analysis of AM build events 3) Correlating in-situ AM process data, generated part defects and part mechanical properties The key R&D question investigated was to determine if these new combined hardware/software tools could be used to successfully quantify defect distributions for parts build via SNL laser powder bed fusion (LPBF) machines, aiming to better understand data-driven process-structure-property- performance relationships. High resolution optical cameras and acoustic microphones were successfully integrated in two LPBF machines and linked to the Peregrine ML software. The software was successfully calibrated on both machines and used to image hundreds of layers of multiple builds to train the ML software in identifying printed part vs powder. The software's validation accuracy to identify this aspect increased from 56% to 98.8% over three builds. Lighting conditions inside the chamber were found to significantly impact ML algorithm predictions from in-situ sensors, so these were tailored to each machine's internal framework. Finally, 3D part reconstructions were successfully generated for a build from the compressed stack of layer-wise images. Resolution differences nearest and furthest from the optical camera were discussed. Future work aims to improve optical resolution, increase process anomalies identified, and integrate more sensor modalities.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Thickness of Proximal Ejecta from the Orientale Basin from Lunar Orbiter Laser Altimeter (LOLA) Data: Implications for Multi-Ring Basin Formation

Quantifying the ejecta distribution around large lunar basins is important to understanding the origin of basin rings, the volume of the transient cavity, the depth of sampling, and the nature of the basin formation processes. We have used newly obtained altimetry data of the Moon from the Lunar Orbiter Laser Altimeter (LOLA) instrument to estimate the thickness of ejecta in the region surrounding the Orientale impact basin, the youngest and best preserved large basin on the Moon. Our measurements yield ejecta thicknesses of approx.2900 m near the Cordillera Mountains, the topographic rim of Orientale, decaying to approx.1 km in thickness at a range of 215 km. These measurements imply a volume of ejecta in the region from the Cordillera ring to a radial range of one basin diameter of approx.2.9 x 10(exp 6)cu km and permit the derivation of an ejecta-thickness decay model, which can be compared with estimates for the volume of excavation and the size of the transient cavity. These data are consistent with the Outer Rook Mountains as the approximate location of the transient cavity s rim crest and suggest a volume of approx.4.8 x 10(exp 6)cu km for the total amount of basin ejecta exterior to this location.

Fassett, Caleb I.a↗
DOE OSTI2025

Refining Methods to Determine the Isotopic Composition of Uranium Particles by Laser Ablation MC-ICP-MS

We report on efforts to mitigate the generation of isotopic anomalies during the ablation of micrometer-sized uranium oxide particles and analysis by MC-ICP-MS. The results of testing on particles of U200 indicate that laser fluence and frequency can affect isotopic data produced by laser ablation, but no settings were tested that could eradicate the signal spiking effect and generation of anomalous isotopic data for 234U/238U and 236U/238U. These anomalies are more frequent in samples with higher 235U enrichments, which is expected given their higher abundances of 234U and 236U. Of the standards tested here, only U005-A was anomaly-free. Efforts to compare the laser traces for particles with normal and anomalous isotopic compositions showed subtle differences in the behavior of the 234U/238U and 236U/238U ratios. However, it would be challenging to identify anomalous data points from a population of unknowns using this distinction, i.e., this is unlikely to be diagnostic. Thus, using current analytical hardware, we cannot eradicate the signal spiking phenomenon and cannot unambiguously identify isotopic anomalies from laser ablation traces. Ultimately, laser ablation ICP-MS would either require dramatic improvement to the ablation process and generation of more homogenous aerosols and/or improvements to detector electronics to identify and correct for the spiking phenomenon. Even if the reliability of the technique could be improved, a broader question to address is whether current data quality is of a high enough standard for laser ablation MC-ICP-MS to be used as a complementary technique to LG-SIMS for Safeguards.

organic↗
DOE OSTI2021

Propagation of Input Uncertainties in Numerical Simulations of Laser Powder Bed Fusion

Laser powder bed fusion has the potential of redefining state-of-the-art processing and production methods, but defect formation and inconsistent build quality have limited the implementation of this process. Numerical models are widely used to study this process and predict the formation of these defects. Presently, the uncertainties of model input parameters and thermophysical properties used by these numerical simulations have not been investigated. In the present study, the uncertainty in these input parameters and material properties are quantified for laser powder bed fusion, with and without a simulated powder bed, to determine their influence on the predictive accuracy of an experimentally validated numerical model. Accounting for all possible sources of uncertainty quickly becomes computationally expensive on account of the curse of dimensionality. Uncertainty in laser absorption, solid, and liquid specific heat of the metal were found to have the largest effect on model prediction reliability with or without the use of a powder bed. Results also illustrate that accounting for these three uncertain parameters still captures the majority of model prediction uncertainty. Furthermore, the methodology of this study may be used to understand the uncertainty in as-built microstructure through propagation to microstructure prediction models, or applied under processing conditions where high Péclet numbers are observed and the thermal convection and fluid flow within the molten pool are substantial.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Understanding Flow Characteristics in Metal Additive Manufacturing

In fluid flow, the frictional effects from interior surfaces of flow components create pressure loss across the surface. Understanding this inherent pressure loss due to friction and other phenomena is important when designing a flow system. For conventional manufacturing, friction loss has been empirically studied and is well known in the engineering community. However, newer manufacturing techniques, such as laser powder bed fusion (LPBF), an additive manufacturing technique, need to be understood. The inherent flow conditions resulting from the additive processes were studied. Test samples were printed with the flow path oriented in the vertical direction with different channel diameters to characterize the inherent fundamental flow properties of the process. Moody diagrams were replicated for a greater understanding of possibilities and shortfalls when implementing LPBF into design applications. Experimental flow testing revealed that greater effective sand grain roughness resulted from this process when compared to conventional machining methods. This roughness did not correlate well to the average roughness measured with a laser scanning microscope but was consistent with the average particle size of the powder metal feedstock.

42 ENGINEERING↗