Engineering topics

Bayramian, Andrew J.

Publications and source records attributed to Bayramian, Andrew J..

10 records

DOE OSTI2024

System and method for high power diode based additive manufacturing

The present disclosure relates to a system for performing an Additive Manufacturing (AM) fabrication process on a powdered material, deposited as a powder bed and forming a substrate. The system makes use of a laser for generating a laser beam, and an optical subsystem. The optical subsystem is configured to receive the laser beam and to generate an optical signal comprised of electromagnetic radiation sufficient to melt or sinter the powdered material. The optical subsystem uses a digitally controlled mask configured to pattern the optical signal as needed to melt select portions of a layer of the powdered material to form a layer of a 3D part. A power supply and at least one processor are also included for generating a plurality of different power density levels selectable based on a specific material composition, absorptivity and diameter of the powder particles, and a known thickness of the powder bed. The powdered material is used to form the 3D part in a sequential layer-by-layer process.

El-Dasher, Bassem S.↗

DOE OSTI2023

Laser pulse shaping for additive manufacturing

The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components. The second beam component has a higher power level and a shorter duration than the first beam component. A mask creates a 2D optical pattern in which only select portions of the second beam components can irradiate the powder particles. The first beam component heats the powder particles close to a melting point, where the particles experience surface tension forces relative to the interface layer. While the particles are heated, the second beam component further heats the particles and also melts the interface layer before the surface tension forces can act on and distort the particles, enabling the particles and the interface layer are able to bond together.

DeMuth, James A.↗

DOE OSTI2023

Gas cooled faraday rotator and method

To enable several orders of magnitude increases in average power and energy handling capability of Faraday rotators, the technology utilizes high speed gas cooling to efficiently remove thermal loading from the Faraday optic faces while minimizing the thermal wavefront and thermal birefringence by creating a longitudinal thermal gradient. A recirculating gas cooling manifold accelerates the gas over the surface of the slab to create a turbulent flow condition which maximizes the surface cooling rate. The technology further provides a spatially uniform thermal profile on the Faraday slabs.

Bayramian, Andrew J.↗

DOE OSTI2022

Laser pulse shaping for additive manufacturing

DeMuth, James A.↗

DOE OSTI2022

System and method for forming material substrate printer

A method is disclosed for manufacturing a part via an additive manufacturing process. A solution is used which has a volatile component within which is suspended particles of a powdered material. The solution is heated until it at least one of begins boiling or is about to begin boiling. The heated solution is then deposited at least at one location on a substrate to help form a layer of the part. The volatile component then evaporates, leaving only the particles of powdered material. The particles are then heated to the melting point. The deposition and heating operations are repeated to successively form a plurality of layers for the part. The evaporation of the volatile component helps to cool the part.

Demuth, James A.↗

DOE OSTI2022

Scaling high-energy pulsed solid-state lasers to high average power

Techniques are provided for scaling the average power of high-energy solid-state lasers to high values of average output power while maintaining high efficiency. An exemplary technique combines a gas-cooled-slab amplifier architecture with a pattern of amplifier pumping and extraction in which pumping is continuous and in which only a small fraction of the energy stored in the amplifier is extracted on any one pulse. Efficient operation is achieved by propagating many pulses through the amplifier during each period equal to the fluorescence decay time of the gain medium, so that the preponderance of the energy cycled through the upper laser level decays through extraction by the amplified pulses rather than through fluorescence decay.

Erlandson, Alvin C.↗

DOE OSTI2019

Laser pulse shaping for additive manufacturing

A system for additive manufacturing uses a pulsed laser beam with one or more low flux components on the order of kW/cm2, and one or more high flux components on the order of MW/cm2 during the duration of the pulse. The pulsed laser beam is directed onto the powder particles on the substrate thereby melting the powder particles and melting the substrate at the interface layer between the powder and the substrate such that the powder particles bond to the substrate. This is accomplished by using low power (and low cost) lasers to do the majority of the energy transfer, and using high power (and higher cost) lasers to complete the melting process, overcoming the kinetics of powder agglomeration through surface tension forces by partially melting the powder-substrate interface layer before surface tension can take effect on the molten powder particles.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Imprinting high-gradient topographical structures onto optical surfaces using magnetorheological finishing: Manufacturing corrective optical elements for high-power laser applications

Corrective optical elements form an important part of high-precision optical systems. We have developed a method to manufacture high-gradient corrective optical elements for high-power laser systems using deterministic magnetorheological finishing (MRF) imprinting technology. Several process factors need to be considered for polishing ultraprecise topographical structures onto optical surfaces using MRF. They include proper selection of MRF removal function and wheel sizes, detailed MRF tool and interferometry alignment, and optimized MRF polishing schedules. Dependable interferometry also is a key factor in high-gradient component manufacture. A wavefront attenuating cell, which enables reliable measurement of gradients beyond what is attainable using conventional interferometry, is discussed. The results of MRF imprinting a 23 μm deep structure containing gradients over 1.6 μm / mm onto a fused-silica window are presented as an example of the technique’s capabilities. As a result, this high-gradient element serves as a thermal correction plate in the high-repetition-rate advanced petawatt laser system currently being built at Lawrence Livermore National Laboratory.

42 ENGINEERING↗

DOE OSTI2015

Method and system for suppression of stimulated Raman scattering in laser materials

A composition of matter is provided having the general chemical formula K(H,D).sub.2P(.sup.16O.sub.x,.sup.18O.sub.y).sub.4, where x<0.998 or y>0.002, and x+y.apprxeq.1. Additionally, a method of fabricating an optical material by growth from solution is provided. The method includes providing a solution including a predetermined percentage of (H,D).sub.2.sup.16O and a predetermined percentage of (H,D).sub.2.sup.18O, providing a seed crystal, and supporting the seed crystal on a platform. The method also includes immersing the seed crystal in the solution and forming the optical material. The optical material has the general chemical formula K(H,D).sub.2P(.sup.16O.sub.x,.sup.18O.sub.y).sub.4, where x<0.998 or y>0.002, and x+y.apprxeq.1.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Electro-optic device with gap-coupled electrode

An electro-optic device includes an electro-optic crystal having a predetermined thickness, a first face and a second face. The electro-optic device also includes a first electrode substrate disposed opposing the first face. The first electrode substrate includes a first substrate material having a first thickness and a first electrode coating coupled to the first substrate material. The electro-optic device further includes a second electrode substrate disposed opposing the second face. The second electrode substrate includes a second substrate material having a second thickness and a second electrode coating coupled to the second substrate material. The electro-optic device additionally includes a voltage source electrically coupled to the first electrode coating and the second electrode coating.

42 ENGINEERING↗