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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

On-target uniformity of the OMEGA 60-beam inertial confinement fusion laser

Successful direct-drive inertial confinement fusion (ICF) experiments require excellent on-target laser 9 irradiance uniformity maintained over the duration of the pulse. Achieving this symmetry relies on maintaining an 10 energy, power, and fluence balance among all beams in a multibeam laser system. As a result of the improvements 11 described in this paper, the OMEGA 60-beam laser performance has been assessed at approximately 2% on-target 12 irradiance nonuniformity using an updated performance assessment metric that accounts for the laser diagnostic noise 13 floor. The performance is measurement-limited, prompting the need for an improved diagnostic suite. This manuscript 14 provides a comprehensive first-order assessment of extant status of on-target energy, power, and fluence uniformity 15 and explores avenues for improvements.

Diagnostics↗
DOE OSTI2025

Status and prospects for inertial fusion energy via lasers

Fusion energy is the ultimate clean and limitless energy source, but its development requires overcoming many scientific and technological challenges. For the first time in the 60-year long history of fusion research, ignition and target gain above unity (G>1) were demonstrated in the laboratory at the National Ignition Facility at the Lawrence Livermore National Laboratory in 2022. Turning laser fusion into an energy source requires that the results from single shot experiments be replicated at much higher repetition rates of many shots per second to produce high average power at relatively low cost. Furthermore, this requires the development of new laser technologies, mass production of suitable targets, accurate injection and tracking systems and new materials for the reactor chamber components and final optics. Ultra broadband and deep UV light are laser advances that can dramatically improve the laser energy coupling to the target thereby reducing the laser energy and power requirements.

Fusion energy↗
DOE OSTI2025

Real-time single-element-detection structured illumination optical metrology for laser powder bed fusion

Laser powder bed fusion (LPBF) is a type of metal additive manufacturing which could benefit from improved process monitoring to improve quality control. We demonstrate, for the first time to our knowledge, the coaxial monitoring of melt track formation in steel powder with spatial frequency modulation imaging (SPIFI), an enhanced-resolution imaging technique which uses a photodiode to record one-dimensional images. Using a custom live-display software and a high-speed SPIFI geometry, we offset the SPIFI field of view from the fusing beam to monitor different regions of the LPBF melt pool and surrounding area. This demonstrates the potential of SPIFI to monitor spatial features within the melt pool in real-time with increased data efficiency.

Hunter, Scott (ORCID:0009000886150312)↗
DOE OSTI2026

Thermodynamics of Bimetallic Joints between Titanium and Tantalum Produced by Laser Powder Bed Fusion

Laser powder bed fusion (LBPF) is currently the most mature metal additive manufacturing (AM) technology. While it does not have the same flexibility as directed energy deposition techniques to produce compositional gradients, LPBF can still be used to generate bimetallic parts by depositing one metal on a build plate made of another. Here, in this study, we print combinations of Ti-6Al-4V with Ta and characterize defects that occur at the interface. We use thermodynamic modeling to explain the formation of keyhole porosity and solidification cracks when Ta is built on a Ti baseplate, and the lack of defects when the materials are reversed. By understanding the mechanisms that lead to defect formation, the methodology demonstrated here can be applied to other material systems to efficiently design bimetallic LPBF processes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Physics of laser direct-drive liquid deuterium–tritium wetted foam capsules for inertial confinement fusion

Laser direct-drive liquid deuterium–tritium (DT) wetted foam capsules hold substantial promise for future advancements in inertial confinement fusion (ICF). For this new class of ICF capsules, additive manufacturing (AM) techniques are used to create low aspect ratio spherical shells of a low-density, foam-like CH lattice, which is wetted with cryogenic liquid DT. In the present paper, we discuss key physics issues intrinsic to ignition and burn propagation in laser direct drive wetted foam capsules. These include requirements on laser energy and power, implosion velocity, fuel adiabat, and initial density and dimensions of the CH lattice shell.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Influence of Process Parameter and Build Rate Variations on Defect Formation in Laser Powder Bed Fusion SS316L

Laser powder bed fusion (LPBF) is an additive manufacturing process that has gained interest for its material fabrication due to multiple advantages, such as the ability to print parts with small feature sizes, good mechanical properties, reduced material waste, etc. However, variations in the key process parameters in LPBF may result in the instantiation of porosity defects and variation in build rate. Particularly, volumetric energy density (VED) is a variable that encapsulates a number of those parameters and represents the amount of energy input from the laser source to the feedstock. VED has been traditionally used to inform the quality of the printed part but different values of VED are presented as optimal values for certain material systems. An optimal VED value can be maintained by changing the key process parameters so that various combinations yield a constant value. In this study, an optimal constant VED value is maintained while printing SS316L with variable key processing parameters. Porosity analysis is performed using optical microscopy, as well as X-ray computed tomography, to reveal the volume density and distribution of those pores. Two primary defect categories are identified, namely lack of fusion and porosity induced by balling defects. The findings indicate that, even at optimal VED, variations in process parameters can significantly influence defect type, underscoring the sensitivity of defect formation to the variation of these parameters. Furthermore, a minor change in the build rate, driven by adjustments in process parameters, was found to influence defect categories. These findings emphasize that fine tuning the process parameters and build rate is essential to minimize defects. Finally, fiducial marks have been identified as a source of unintentional porosity defects. These results enable the refinement of process parameters, ultimately optimizing LPBF to achieve enhanced material density and expedite the printing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

All-fiber, discrete arbitrary picket-pulse shaping

Here, a novel all-fiber, hybrid pulse-shaping system based on the temporal stacking of discrete optical picket pulses combined with continuously shaped optical pulses provides 100-ps resolution with the high dynamic range and flexibility required for laser fusion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Stacked-mosaic amplifier and diode delivery concept for kJ-class inertial fusion energy laser driver

We report on a laser amplifier architecture designed as a modular element for scaling to multi-megajoule laser facilities intended for inertial fusion energy (IFE) power plants. This kilojoule-class module features a stacked mosaic of gain media integrated with a diode delivery system for efficient optical pumping of the mosaic-structured gain medium, enabling high-repetition-rate operation at high wall plug efficiencies, necessary for an IFE driver. Details of a diode delivery system capable of pumping the mosaic architecture are presented. Comprehensive numerical modeling demonstrates that the stacked-mosaic approach reduces transverse gain by five orders of magnitude compared to a conventional full-aperture Yb:YAG based amplifier, substantially suppressing transverse amplified spontaneous emission (TASE) and enabling enhanced longitudinal energy extraction. Detailed analysis of thermal management and wavefront distortion in a 4 × 4 mosaic array indicates that temperature gradients and thermally induced aberrations are effectively controlled using gas cooling and commercially available phase-plate and deformable mirror technologies. We further discuss the applicability of a stacked-mosaic architecture to direct-drive IFE schemes, where broad spectral bandwidth is critical, and its compatibility with frequency conversion modules for up-conversion to blue wavelengths. Finally, an example point design for a 10 kJ, 10 Hz Yb:YAG module operating at 175 K with wall-plug efficiency exceeding 10 % is presented, underscoring the feasibility of this approach for next-generation high-energy lasers for IFE drivers. The results establish the stacked-mosaic amplifier as a scalable, robust platform not only for IFE but also for a broad range of advanced scientific and industrial laser applications.

Lasers↗
DOE OSTI2025

Microstructural evaluation of thin-wall sections of 316L stainless steel produced by laser powder-bed fusion processing

Laser powder bed fusion (LBPF) is a method of additive manufacturing (AM) that offers a means to fabricate complex components with features which rely upon the mechanical integrity of thin-wall (less than 0.4 mm thick) structures. The microstructure of a 316L AM thin wall is investigated as metallographically prepared from a cylindrical shell. Optimization is pursued through mechanical polishing and chemical etching to minimize the effects of surface roughness. Microanalysis measurements of the sectioned component reveal the sample has high microstructural fidelity, uniform composition and phase content across grain as well as powder layer boundaries within the thin wall. The results are attributed to a uniform thermal gradient at the part scale during rapid solidification.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Ponderomotive electron physics captured in a single-fluid extended magnetohydrodynamics model

The ponderomotive force, arising from the interaction between electromagnetic waves and plasma, plays a critical role in laser fusion, astrophysical plasmas, and laser diagnostics. Traditionally, modeling this force requires multi-fluid or particle-in-cell simulations due to its strong coupling to electron-scale dynamics. In this work, we demonstrate that a one-fluid, two-temperature extended magnetohydrodynamics (XMHD) model—augmented with a generalized Ohm's law (GOL) including electron inertia—can accurately reproduce key ponderomotive effects. We derive the ponderomotive force within this framework using a phasor-based approach and then validate its nonlinear manifestations through direct numerical simulations in the PERSEUS code, where steepening and density modulation phenomena typically associated with kinetic-scale models are reproduced. These results and prior work establish XMHD as a robust and efficient alternative for modeling nonlinear laser–plasma dynamics, bridging the gap between ideal MHD and fully kinetic approaches.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

On the formation of swelling and related flaws in laser powder bed fusion

Process monitoring in laser powder bed fusion additive manufacturing can provide insights into stochastic anomalies, melt pool and plume dynamics, and part quality. Swelling, a build anomaly where overbuilt material protrudes through the powder layer after recoating, is readily detectable in post-recoat visible light images of the powder bed. Here, this work identifies several of the underlying mechanisms driving swelling formation by analyzing the influence of processing parameters, laser scan paths, and build plate locations on the presence of swelling detected in situ. Swelling near the edge of the part and swelling in the internal region of the part are shown to correlate with different process conditions. Edge and internal swelling may be driven by different phenomena, with edge swelling predominately occurring on the edge of a part facing the laser module and correlated to clusters of near-surface voids (detected with X-ray computed tomography). A larger spot size, higher laser power, and lower scan velocity also increased the presence of edge swelling. Laser spot size and scan path influenced internal swelling, which occurred preferentially with a larger spot size and in regions with large melt pools, caused by localized heat accumulation due to non-optimal processing parameters or scan path strategies. For coupons processed with a slicer-defined maximum scan vector length, swelling seldom occurred at internal vector-stripe boundaries. These results provide a mechanistic understanding of how swelling can be linked to material flaws, insight into how some instances of swelling can be avoided, and evidence supporting the use of swelling as an in situ indicator for quality assurance and part qualification.

Anomaly↗
DOE OSTI2025

2025 Peregrine in-situ monitoring and training dataset for laser powder bed fusion and binder jet printers

Peregrine, a software tool developed at Oak Ridge National Laboratory (ORNL), was used to collect and analyze in-situ monitoring (ISM) data from a Concept Laser M2 (Colibrium Additive) laser powder bed fusion (L-PBF) printer and an ExOne Innovent (Desktop Metal) binder jet printer. Data for four builds (print jobs) were saved to HDF5 (high performance data) files for release. Additionally, process anomalies were annotated by the authors across 37 image stacks (i.e., print layers) and are also provided as HDF5 files.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Investigating the Potential and Limitations of Fast Scanning Calorimetry to Simulate the Laser Power Bed Fusion Coalescence Process

Laser-Based Powder Bed Fusion (PBF-LB) • PBF-LB is part of one of seven additive manufacturing techniques • Layer wise printing that selectively coalesces discrete powder particles into a solid object o Advantages: Low anisotropy, use of engineering grade materials o Weaknesses: lack of method standardization, challenges in controlled post print quality

Blackman, Malik A. [Georgia Inst. of Technology, A↗
DOE OSTI2025

The influence of laser power modulation on melt pool dynamics in laser powder bed fusion

While the majority of laser powder bed fusion (LPBF) metal additive manufacturing uses a continuous wave (CW) laser heat source, some commercial applications of LPBF additive manufacturing instead involve the modulation of the laser power on tens-of-microsecond timescales as an adjustable process variable. This article reports the use of in situ, high speed x-ray and optical imaging to probe melt pool fluid flow, defect formation, and nearby powder motion during LPBF with both modulated and CW laser heat sources. We observe melt pool dynamics unique to modulated laser melting even at very high duty cycles that are related to fluctuations in vapor depression depth, complex pore formation mechanisms, and changes to denudation physics when compared to CW melting. These behaviors are present in Ti–6Al–4V, 316L stainless steel, and AL1100 alloys but vary slightly as a function of material, indicating a substantial dependence on the viscosity and surface tension of the liquid metal. While high duty cycles produce weld tracks of comparable quality to CW melting, lower duty cycles introduce substantial defect concentrations. At intermediate duty cycles, careful control of modulation parameters can repeatably and precisely yield one pore per laser pulse, suggesting a method for intentionally inserting engineered porosity at specific sites during an LPBF build.

3D printing↗
DOE OSTI2026

In situ study on radiation response of tungsten manufactured by laser powder bed fusion

Tungsten (W) produced by laser powder bed fusion (LPBF) was examined by in situ Krypton (Kr) ion irradiation at 400 °C up to 2.52 displacements per atom (dpa) to investigate its radiation response. Dislocation loops with identical Burgers vectors form aligned raft structures, inducing significant grain misorientation accumulation. Defect saturation was observed beyond 0.36 dpa, marked by constant loop density and raft spacing. WO 3 nanoparticles are found in the as-printed matrix and served as efficient defect sinks. Dislocation loops were absorbed at the W/WO 3 interface, facilitating defect annihilation and suppressing defect accumulation. In conclusion, these findings highlight the role of LPBF microstructure and oxide interfaces in mediating radiation-induced defect evolution, offering insights for designing radiation tolerant W-based materials.

Defect sink↗
DOE OSTI2025

Laser wavelength dependence of laser imprint

In laser direct-drive inertial confinement fusion, laser imprint is one of the major causes of degradation in target performance through its seeding of hydrodynamic instabilities. Early experiments and simulations have shown that laser imprint could be mitigated with a longer laser wavelength because of its lower critical density and longer conduction zone. Building upon this work, we explore a scenario where the laser wavelength during the picket pulse differs from that of the main pulse in order to gain the benefit of reduced imprint, while avoiding losses in drive coupling efficiency or an increase in laser-plasma instabilities. A series of 2D radiation-hydrodynamic simulations, which test three different laser wavelengths for the picket pulse, has been performed, where the intensity of the picket pulse is adjusted in order to maintain the same implosion adiabat. A detailed analysis of the growth of the mass density modulations at the ablation front over a large range of mode numbers confirms that the laser imprint can be mitigated with a picket pulse operating at a longer wavelength than the main pulse because of the longer conduction zone and enhanced thermal smoothing. The amplitude of the ablation front modulations is found to be lower for all mode numbers, which reduces the seeding of the Rayleigh–Taylor instability without affecting the mode growth rates.

Fourier analysis↗
DOE OSTI2026

Establishing an acoustic-property relationship in laser powder bed fusion with machine learning

Quality control of Laser Powder Bed Fusion (PBF-LB) additively manufactured parts is an important hurdle inhibiting the technology’s use structural applications. Acoustic monitoring of the laser powder bed fusion process can detect defects in-situ that are known to degrade mechanical properties. However, processing-structure-property (PSP) relationships are required to extrapolate from detected defects to part performance. Here, this study explores how acoustics may be a suitable signature linking processing conditions to properties, thus effectively substituting for structure in the PSP relationship. Establishing such a relationship would enable a part’s mechanical performance to be directly predicted from its acoustic signature, reducing the need for destructive testing or microstructural analysis to ensure a part will meet performance requirements. One hundred CoCrFeMnNi high entropy alloy tensile bars were printed across 13 process conditions in a series of 6 prints. The acoustic signatures of these tensile bars were used to train machine learning models to predict each part’s mechanical properties. By using both process information and acoustic information to predict mechanical properties, yield strength was predicted 18% more accurately and ductility to failure was predicted 10% more accurately than is achieved when using duplicate parts to predict part performance. Finally, individual acoustic frequencies were investigated to determine why acoustic signatures improve mechanical property predictions and the potential physical origins of these signatures. This work demonstrates how blending acoustics, process information, and machine learning can provide in-situ diagnostics of mechanical properties and improve the reliability of the PBF-LB process.

Acoustic emission↗