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All sources NASA NTRS DOE OSTI

DOE OSTI2024

Robustness and printed sensor qualification

A limiting factor of additive manufactured (AM) sensors for in-pile applications is the development of appropriate interconnection and packaging strategies that can maintain reliable performance in extreme environments. Failure mechanisms in these harsh conditions could include, but not limited to, materials interaction (i.e., intermetallic formation) and coefficient of thermal expansion (CTE) mismatch between the individual components of the sensors. To mitigate premature failure and enable the successful sustained operation of AM sensors, non-destructive qualification tests are used as an intermediate process control step used for verifying robustness and reliability of the sensor before they are deployed. A materials system of interest is the use of barium strontium titanium oxide (BST) films on stainless steel 316L (SS316L) substrate. Due to BST’s high dielectric constant and tunable dielectric properties, there is an interest for its application as an insulation/encapsulation layer for capacitive strain gauges when printed on structural materials. Previous work on the BST/SS316L material system, however, showed that the BST cracks when exposed to temperatures up to 600 °C due to CTE mismatch between the printed BST film and the metallic substrate. When comparing different fabrication techniques, less surface cracking was observed in the samples that deposited thinner (i.e., 2-20 μm) than samples that were thicker (i.e., 135 µm – 300 µm). The objective of this report is to establish a qualification process that will determine and address any challenges (i.e., mechanical failure of thick prints) of the AM sensor prior to its application in experimental tests. To demonstrate the qualification process in this report, laser spallation and uniaxial tensile tests using dynamic and quasi-static loading, respectively, will be discussed.

36 - MATERIALS SCIENCE↗

DOE OSTI2024

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↗

DOE OSTI2022

Development of Quality Control Methods for Robust and Reliable Sensor Design

The successful adoption of additive manufacturing for the rapid prototyping of printed sensors requires the establishment of quantifiable metrics that can interrogate device performance. One measure of performance is the adhesion strength between the substrate and sensor interface, which is critical since the strength of this interface can dictate the accuracy and reliability of the printed sensor. In this work, a non-contact laser-induced spallation technique was used to quantify the adhesion of silver prints on an aluminum alloy substrate. 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 supports the establishment of process control steps that are necessary for verifying the reliability of printed devices prior to its deployment in critical experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties).To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗

DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗

NASA NTRS1986

Identification of cosmogenic argon components in Allende by laser microprobe

New techniques are presented for using a laser microprobe to determine the spallation argon systematics of calcium-aluminum inclusions. The Ar-38(s) amounts determined for melilite and anorthite in a coarse-grained inclusion from Allende are 2.9 x 10 to the -8th and 1.3 x 10 to the -8th cc/g, respectively. The ratio of the amounts is consistent with the calcium contents of these two minerals. The Ar-38(s) amount determined for a fine-grained inclusion from Allende is 1.1 x 10 to the -8th cc/g. Calcium and potassium amounts were determined from irradiated samples of the same inclusions so that production of Ar-38 from calcium during the cosmic ray exposure of Allende could be determined for these samples. The production observed was 12.4 + or - 2.1 x 10 to the -8th cc STP Ar-38/g Ca for the coarse-grained inclusion and 9.9 + or - 2.4 cc STP Ar-38/g Ca for the fine-grained inclusion. No evidence of unusual exposure was observed in the two inclusions studied.

Kirschbaum, C.↗

DOE OSTI2023

Laser and optical transport line for laser-based ion beam diagnostics and control in the SNS linear accelerator

We report our recent upgrade of the laser and optical transport line for the laser-based ion beam diagnostics (laser wire) system at the linear accelerator (linac) of the Spallation Neutron Source (SNS). A new light source based on diodepumped solid-state laser amplifiers has been developed to provide near diffraction-limited laser beam with a variety of pulse structures. The free-space optical transport line has been modified to include image relay optics with remote control, which greatly improved the laser beam quality and position stability at individual measurement stations. The upgraded system enables novel beam diagnostics/control capabilities including longitudinal profile measurement and high-energy proton beam extraction from the SNS linac.

Liu, Yun↗

DOE OSTI2024

Rapid dissolution without elemental fractionation by laser driven hydrothermal processing

Traditional dissolution of geologic samples often requires a significant time investment. Here, we present an alternative method for the dissolution of geologic materials using laser-driven hydrothermal processing (LDHP). LDHP uses laser energy directed onto a submerged sample, which increases the temperature and pressure at the liquid–sample interface and drives the hydrothermal dissolution coupled with photomechanical spallation, an ablative process. This uses focused 527 nm laser energy at 40 W average power, 1 kHz pulse repetition rate, and 115 ns pulse duration. Importantly, when LDHP is performed on basalt geostandards (BCR-2 and BHVO-2) using the conditions outlined, we show that LDHP does not produce significant elemental fractionation and, thus, can be considered an alternative processing method to traditional mechanical crushing and acid digestion. Additionally, it is possible using LDHP to utilize the spatially confined beam to target and selectively isolate individual phases in a rock, potentially alleviating the need for mechanical separation of inclusions that are difficult to physically isolate. Furthermore, using this outlined method of LDHP, we demonstrate full dissolution of 120 mg of obsidian in 85 minu, meaning that LDHP is a potentially very useful method when sample processing is time sensitive.

58 GEOSCIENCES↗

DOE OSTI2025

Laser beam pointing stabilization using analog position-sensitive diodes

Laser wire scanners have been used for ion beam profile and emittance measurements at the Spallation Neutron Source linear accelerator. Due to propagation distances exceeding 100 m, reliable measurements require laser beam stabilization, previously accomplished with a feedback control loop using a digital camera as a position sensor [Hardin et al., Opt. Express 19, 2874 (2011)]. Here, this paper presents an upgraded pointing stabilization system utilizing analog position-sensitive diodes (PSDs) as the position detector, optimized with an optical diffuser. The new system significantly surpasses the previous system by offering an order-of-magnitude improvement in radiation tolerance and a bandwidth limited only by the burst repetition rate of the laser beam. Operating with a 60-Hz burst mode laser, the new system effectively suppresses laser beam drifts up to 30 Hz, compared to the previous system’s 4 Hz limit. In addition, the amplitude of spectral components below 0.1 Hz was reduced by a factor of more than 100, which is over seven times greater than was achieved by the previous system.

Data acquisition↗

DOE OSTI2023

High deuteron and neutron yields from the interaction of a petawatt laser with a cryogenic deuterium jet

A compact high-flux, short-pulse neutron source would have applications from nuclear astrophysics to cancer therapy. Laser-driven neutron sources can achieve fluxes much higher than spallation and reactor neutron sources by reducing the volume and time in which the neutron-producing reactions occur by orders of magnitude. We report progress towards an efficient laser-driven neutron source in experiments with a cryogenic deuterium jet on the Texas Petawatt laser. Neutrons were produced both by laser-accelerated multi-MeV deuterons colliding with Be and mixed metallic catchers and by d (d,n) 3 He fusion reactions within the jet. We observed deuteron yields of 10 13 /shot in quasi-Maxwellian distributions carrying ~8-10% of the input laser energy. We obtained neutron yields greater than 10 10 /shot and found indications of a deuteron-deuteron fusion neutron source with high peak flux (>10 22 cm -2 s -1 ). The estimated fusion neutron yield in our experiment is one order of magnitude higher than any previous laser-induced dd fusion reaction. Though many technical challenges will have to be overcome to convert this proof-of-principle experiment into a consistent ultra-high flux neutron source, the neutron fluxes achieved here suggest laser-driven neutron sources can support laboratory study of the rapid neutron-capture process, which is otherwise thought to occur only in astrophysical sites such as core-collapse supernova, and binary neutron star mergers.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS1972

Gas analysis of Apollo 12, 14, and 15 samples by laser-probe mass spectrometry

Solar wind gases, cosmogenic gases from high energy spallation reactions from soxmic rays, and radiogenic gases from decay of radioactive potassium and from uranium and thorium isotopes were analyzed in lunar materials. Details are presented on two aspects of the studies: (1) The spatial distribution of Ar-40/Ar-38 ages in lunar breccia 14301 was determined. The ages of clasts within this breccia are 3.68 + or - 0.09 and 2.9 + or - 0.3 x 10 to the 9th power years. Parentless radiogenic Ar-40 exists within the fine-grained matrix. (2) The distribution of helium, neon, and argon isotopes within Apollo 15 samples results primarily from fractionated solar wind gases, accompanied by small quantities of cosmogenic gases. Comparison of this Apollo 15 data with Kapoeta and Fayetteville meteorite and Apollo 12 and 14 data indicates that solar wind implantation followed by fractionation of the gases was primarily responsible for incorporation of original gas phase within solid bodies of the solar system.

Imegrue, G. H.↗

DOE OSTI2024

Implementation of a laser–neutron pump–probe capability for inelastic neutron scattering

Knowledge about nonequilibrium dynamics in spin systems is of great importance to both fundamental science and technological applications. Inelastic neutron scattering (INS) is an indispensable tool to study spin excitations in complex magnetic materials. However, conventional INS spectrometers currently only perform steady-state measurements and probe averaged properties over many collision events between spin excitations in thermodynamic equilibrium, while the exact picture of re-equilibration of these excitations remains unknown. In this paper, we report on the design and implementation of a time-resolved laser–neutron pump–probe capability at hybrid spectrometer (beamline 14-B) at the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory. This capability allows us to excite out-of-equilibrium magnons with a nanosecond pulsed laser source and probe the resulting dynamics using INS. Here, we discussed technical aspects to implement such a capability in a neutron beamline, including choices of suitable neutron instrumentation and material systems, laser excitation scheme, experimental configurations, and relevant firmware and software development to allow for time-synchronized pump–probe measurements. We demonstrated that the laser-induced nonequilibrium structure factor is able to be resolved by INS in a quantum magnet. In conclusion, the method developed in this work will provide SNS with advanced capabilities for performing out-of-equilibrium measurements, opening up an entirely new research direction to study out-of-equilibrium phenomena using neutrons.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2026

Phase Drifts and Signal Dispersion in Coaxial Cables

Phase reference distribution is a critical challenge in modern linear particle accelerators, such as European Spallation Source (ESS), European X-ray Free Electron Laser (E-XFEL), or Proton Improvement Plan II (PIP-II). Similar issues may also arise in other RF systems that need to synchronize many independent circuits. Achieving low phase drift of the reference signal requires careful selection of cables and their environmental operating conditions. Due to the limited data provided by cable manufacturers, it is necessary to characterize the cable performance. This article investigates the phase drifts in coaxial cables and presents a dedicated measurement methodology. The dispersion characteristics of the cables are also examined. The measurement results of various coaxial cables are presented, along with conclusions and practical guidelines for designers of phase reference distribution lines.

coaxial cables↗

DOE OSTI2022

Demonstration of non-destructive and isotope-sensitive material analysis using a short-pulsed laser-driven epi-thermal neutron source

Neutrons are a valuable tool for non-destructive material investigation as their interaction cross sections with matter are isotope sensitive and can be used complementary to x-rays. So far, most neutron applications have been limited to large-scale facilities such as nuclear research reactors, spallation sources, and accelerator-driven neutron sources. Here we show the design and optimization of a laser-driven neutron source in the epi-thermal and thermal energy range, which is used for non-invasive material analysis. Neutron resonance spectroscopy, neutron radiography, and neutron resonance imaging with moderated neutrons are demonstrated for investigating samples in terms of isotope composition and thickness. The experimental results encourage applications in non-destructive and isotope-sensitive material analysis and pave the way for compact laser-driven neutron sources with high application potential.

36 MATERIALS SCIENCE↗

NASA NTRS1982

Spallation of the Galileo probe heat shield

The Galileo probe heat shield will encounter severe radiative and convective heating during entry into Jupiter's atmosphere. The shield is made of two different carbon phenolic composites; one is chopped-molded, and the other is tape-wrapped, both of which tend to spall under intense heating conditions. To characterize this phenomenon, an experimental program, using a gasdynamic laser, was initiated. Tests were performed at a variety of radiation intensities, and both the total and spallation mass-loss rates were measured and correlated with intensity. These correlations were then applied to calculated flight heating conditions for two model atmospheres. Entry of a 310-kg probe into the nominal atmosphere would result in a spallation mass loss of 6.3 kg, or 7.4% of the expected thermochemical mass loss. Similarly, entry of that probe into the cool-dense atmosphere would result in 11.9 kg of spallation, or about 10% of the expected thermochemical mass loss.

Lundell, J. H.↗

DOE OSTI2022

On possibility of low-emittance high-energy muon source based on plasma wakefield acceleration

We report plasma wakefield acceleration (PWA) channels are characterized by very high accelerating gradients and very strong focusing fields. We propose to employ these properties for effective production of low emittance high energy muon beams, consider muon beam dynamics in the PWFA cell and analyze various options and potential of the PWA-based muon sources.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Dynamic response of 17-4 stainless steel as a function of manufacturing method and heat treatment

We present a series of plate-impact experiments on 17-4 stainless steel to study the effect of manufacturing method and heat treatment on the Hugoniot elastic limit (HEL), Hugoniot, phase transformation stress, and spallation strength. Two traditional manufacturing methods were considered, wrought processing and casting, as well as two additive manufacturing methods, laser powder-bed fusion (LPBF) and wire-fed electron beam (EBAM). For both LPBF and EBAM 17-4 stainless steel variants, two billets were printed, enabling the application of two unique heat treatments. The HEL stress depended heavily on the thermal history, with the HEL increasing after the formation of Cu-rich precipitates via heat treatment. The Hugoniot response both below and above the phase transition was unaffected by the manufacturing method or heat treatment. The phase transition stress depended heavily on the thermal history, with its variation being attributed to the presence of various microstructural features. This is supported by a marked increase in the phase transition stress after precipitation hardening. These results suggest that the notion of the phase transition stress being dictated by bulk composition is an oversimplification and the stress fields generated by the meso-scale structure are a dominant force. The spallation strength was lower in the cast material compared to all other 17-4 stainless steel variants due to the presence of brittle δ-ferrite inclusions. Additionally, a drop in the tensile strain-rate was observed in the spallation response above the phase transition stress, which was hypothesized to stem from the kinetics of the reversion to the low-pressure phase during spall.

Compressive stress↗

DOE OSTI2025

Defect And Damage Characterization Of Additively Manufactured Titanium Alloy Ti-5553 Using Traditional Computed Tomography Volume Segmentation And Machine Learning Algorithms

The mechanical response of a component is affected by defects, such as porosity, arising from the laser powder bed fusion (LPBF) fabrication process. Thus, it is important to develop accurate and efficient inspection methods for identifying porosity. In this work, porosity identified in an X-ray computed tomography (XCT) volume of a Ti-5553 coupon was compared to pores identified in a serial sectioned volume that represented the ground truth. The porosity of the XCT scan was identified using contrast-based, ISO-based, and machine learning (ML) methods for segmentation. Large inherent porosity was easy to identify, but the ISO thresholding still struggled due to the intensity gradient resulting from both the beam hardening in XCT and the uneven lighting of the serial sectioning panels. Further, the results show that ML-based methods were better suited for identifying small pores and reducing the amount of false positives. Additionally, high strain-rate impact testing was done on some of the XCT samples as well as post-mortem XCT inspection, and the same suite of segmentation and quantification tools were used to identify the large spallation cavities. The comparison of porosity pre- and post-mortem provides insight on the influence of the LPBF porosity on the formation of spall cavities.

36 MATERIALS SCIENCE↗