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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 235 records · Page 13

Communications satellites in the fiber optics era

Three new satellite technologies, i.e., electronically hopped antenna beams, on-board switching, and laser intersatellite links, will soon be tested on experimental satellites. These technologies will enable future satellites to capture significant amounts of data and voice traffic. Fiber cables on the continents will dominate trunking routes, but satellites functioning as switches will be more flexible and reliable, and will cost less than terrestrial-based switches. When satellite switches and laser intersatellite links are combined, the resulting satellite networks will provide cost-effective, independent voice/data networks in the coming global village. They will augment existing terrestrial networks for thin route and low data rate links.

Lovell, R. R.↗

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↗

Post-build stress-relief optimization for laser powder bed fusion 316H stainless steel

Nuclear energy remains a critical component of a diversified and efficient energy portfolio, offering reliable, high-capacity, and low-carbon power. However, in the U.S., aging infrastructure and the slow qualification and deployment of advanced materials and manufacturing techniques hinder progress in next-generation reactor technologies. This study explores the application of laser powder bed fusion (LPBF) additive manufacturing for stainless steel 316H, with a focus on optimizing post-build heat treatments to enhance material properties for high-temperature nuclear applications. The research targets the optimization of stress-relief temperatures to alleviate postbuild residual stresses, ensuring improvements in the microstructural corelated properties. A series of microstructural and mechanical evaluations were performed on LPBF-printed SS-316H samples which were subjected to annealing at temperatures varying between 650 °C and 850 °C. X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses revealed that increasing the heattreatment temperature accelerated dislocation recovery. Vickers microhardness measurements showed an initial reduction in values, followed by stabilization over extended durations at all the temperatures. While higher temperatures facilitated faster recovery, they also promoted carbide precipitation along grain and solidification cell boundaries, narrowing the safe processing window. In contrast, heat treatment at 650°C preserved the cellular substructure and enabled controlled carbide precipitation over time. In conclusion, these findings highlight the importance of time–temperature optimization and suggest that 650°C for up to 2 h provides the most favorable balance between recovery and carbide control for a stress-relief treatment.

316 stainless steel↗

Development of Fiber-Based Laser Systems for LISA

We present efforts on fiber-based laser systems for the LISA mission at the NASA Goddard Space Flight Center. A fiber-based system has the advantage of higher robustness against external disturbances and easier implementation of redundancies. For a master oscillator, we are developing a ring fiber laser and evaluating two commercial products, a DBR linear fiber laser and a planar-waveguide external cavity diode laser. They all have comparable performance to a traditional NPRO at LISA band. We are also performing reliability tests of a 2-W Yb fiber amplifier and radiation tests of fiber laser/amplifier components. We describe our progress to date and discuss the path to a working LISA laser system design.

Numata, Kenji↗

Enhancement of harmonic generation by an intense driving laser with high-order waveguide modes in a high-pressure gas-filled hollow waveguide

High-order harmonics have been widely used as reliable tabletop coherent radiation sources recently, but their applications have often been limited by the available pulse energy. Here, we report that by using an overdriven intense laser in a long waveguide with high-pressure gas, phase matching can be achieved in three distinct “regimes”. In the third regime, favorable phase matching is achieved at near-axis positions to enhance harmonic yields. Our results are supported by a full theoretical analysis, and we demonstrate that coupling of the driving laser with the high-order waveguide modes (instead of the fundamental mode used in most prior experiments) is responsible for achieving phase matching. Furthermore, we establish that this phase matching (and harmonic enhancement) is robust, and a scaling relation is derived for the necessary waveguide and gas parameters, allowing our predictions to be tested immediately in any laboratory today.

Li, Baochang [Nanjing University of Science and Te↗

Epitaxial Growth Development: CRADA Final Report

The purpose of this CRADA is to assist Trumpf Photonics in developing a procedure to grow ZnSe epilayers on the (110) facets of AlGaAs/InGaAs laser diodes that will provide high degrees of electronic passivation and performance reliability. Work will be divided into four tasks: 1) characterization of material growth at Trumpf Photonics, 2) development of a highly effective AlGaAs facet cleaning procedure at NREL, 3) development of a ZnSe epitaxy procedure at NREL, and 4) transfer of the procedures developed at NREL to the Trumpf Photonics site. This CRADA is designed to last 3 years total.

36 MATERIALS SCIENCE↗

Manufacturing and producibility technology

Activities of the manufacturing/producibility working group within the Advanced High-Pressure O2/H2 Technology Program are summarized. The objectives of the M/P working group are: to develop and evaluate process and manufacturing techniques for advanced propulsion hardware design and selected materials; and to optimize the producibility of (SSME) components and assemblies by improved performance, increased life, greater reliability, and/or reduced cost. The technologies being developed include: plasma arc, laser, and inertia welding; combustion chamber and turbine blade coatings; coating processes; high performance alloy electroforming; and process control technology.

Hankins, J. D.↗

Laser Systems

Tunable diode lasers are employed as radiation sources in high resolution infrared spectroscopy to determine spectral characteristics of gaseous compounds. With other laser systems, they are produced by Spectra-Physics, and used to monitor chemical processes, monitor production of quantity halogen lamps, etc. The Laser Analytics Division of Spectra-Physics credits the system's reliability to a program funded by Langley in the 1970s. Company no longer U.S.-owned. 5/22/97

Source record↗

Progress and Plans for a US Laser System for the LISA Mission

NASA Goddard Space Flight Center is developing a master oscillator power amplifier (MOPA) laser transmitter for the ESA-led Laser Interferometer Space Antenna (LISA) mission. Taking advantage of our space laser experience and the emerging telecom laser technology, we are developing a full laser system for the LISA mission. Our research effort has included both master oscillator (MO) and power amplifier (PA) developments, and their environmental testing and reliability for space flight. Our current baseline for the MO is a low-mass, compact micro NPRO (m-NPRO) laser. The amplifier uses a robust mechanical design based on fiber components. We have performed laser system noise tests by amplitude- and frequency-stabilizing the PA output. We will describe our progress and plans to demonstrate a TRL 6 laser system, which is an essential step toward qualifying lasers for space applications, by 2021.

lasers↗

Seeding for laser velocimetry in confined supersonic flows with shocks

There is a lack of firm conclusions or recommendations in the open literature to guide laser velocimeter (LV) users in minimizing the uncertainty of LV data acquired in confined supersonic flows with steep velocity gradients. This fact led the NASA Lewis Research Center (LeRC) in Cleveland (Ohio, USA), and the Institute of Propulsion Technology of DLR in Cologne (Germany) to a joint research effort to improve reliability of LV measurements in supersonic flows. Over the years, NASA and DLR have developed different expertise in laser velocimetry, using different LV systems: Doppler and two-spot (L2F). The goal of the joint program is to improve the reliability of LV measurements by comparing results from experiments in confined supersonic flows performed under identical test conditions but using two different LV systems and several seed particle generators. Initial experiments conducted at the NASA LERC are reported in this paper. The experiments were performed in a narrow channel with Mach number 2.5 flow containing an oblique shock wave generated by an immersed 25-dg wedge.

Lepicovsky, J.↗

Long-term thermal aging behavior and strength reduction in a laser powder bed fusion 316H stainless steel

The long-term thermal stability of structural alloys is essential for ensuring the safe and reliable operation of nuclear reactors and other power plants. While extensive research has explored the effects of thermal aging on conventional stainless steels, the behavior of additively manufactured (AM) alloys remains less understood. This study examines the thermal aging response of laser powder bed fusion (LPBF) 316H stainless steel (SS) at temperatures ranging from 550 °C to 750 °C over durations of up to 10,000 h (approximately 1.14 years). Advanced characterization techniques, including electron microscopy and synchrotron X-ray diffraction, were used to investigate dislocation recovery and phase evolution. Based on these findings, a time-temperature-precipitation (TTP) diagram was developed for LPBF 316H SS, revealing a 10- to100-fold acceleration in precipitation kinetics compared to wrought 316H SS. A physics-informed model was calibrated using the short-term experimental data, enabling predictions of average precipitate sizes, volume fractions of M 23 C 6 and Laves phases, and changes in molybdenum solute concentration for aging up to 1 × 10⁶ h (114 years). These microstructural insights were further utilized to estimate yield strength and extrapolate strength reduction factors over the extended aging period. Despite the accelerated aging kinetics, LPBF 316H SS demonstrated superior yield strength retention compared to its wrought counterpart. In conclusion, this study establishes a framework for evaluating long-term performance using short-term experimental data and supports the accelerated qualification of AM materials for high-temperature structural applications.

Laser powder bed fusion↗

Quantitative Species Measurements in Microgravity Combustion Flames using Near-Infrared Diode Lasers

Understanding the physical phenomena controlling the ignition and spread of flames in microgravity has importance for space safety as well as for characterizing dynamical and chemical combustion processes which are normally masked by buoyancy and other gravity-related effects. Unfortunately, combustion is highly complicated by fluid mechanical and chemical kinetic processes, requiring the use of numerical modeling to compare with carefully designed experiments. More sophisticated diagnostic methods are needed to provide the kind of quantitative data necessary to characterize the properties of microgravity combustion as well as provide accurate feedback to improve the predictive capabilities of the models. Diode lasers are a natural choice for use under the severe conditions of low gravity experiments. Reliable, simple solid state operation at low power satisfies the operational restrictions imposed by drop towers, aircraft and space-based studies. Modulation wavelength absorption spectroscopy (WMS) provides a means to make highly sensitive and quantitative measurements of local gas concentration and, in certain cases, temperature. With near-infrared diode lasers, detection of virtually all major combustion species with extremely rapid response time is possible in an inexpensive package. Advancements in near-infrared diode laser fabrication technology and concurrent development of optical fibers for these lasers led to their use in drop towers. Since near-infrared absorption line strengths for overtone and combination vibrational transitions are weaker than the mid-infrared fundamental bands, WMS techniques are applied to increase detection sensitivity and allow measurement of the major combustion gases. In the first microgravity species measurement, Silver et al. mounted a fiber-coupled laser at the top of the NASA 2.2-sec drop tower and piped the light through a single-mode fiber to the drop rig. A fiber splitter divided the light into eight channels that directed the laser beam across a methane or propane diffusion jet flame. The light beams were recaptured by a set of gradient index lenses, coupled back into separate fiber optic lines, and transmitted back to detectors and electronics in the instrument package. In these experiments a 6-mm od fiber cable (containing the nine optical fibers) fell with the drop rig. Using separate detection and demodulation channels, spatial and temporal (up to 20 Hz) maps of water vapor and methane concentrations were obtained at differing heights in the flames. While this apparatus was useful from a demonstration standpoint, several drawbacks needed attention before useful scientific measurements could be obtained. First, eight lines of sight are somewhat insufficient for detailing the spatial profiles of the gas. Second, multiple detection channels operating in parallel are both expensive and present a challenge for accurate calibration. As a result, a newer scanning system was developed in our first contract under this program. The primary characteristic of this system is that it contains a single detection channel and achieves "continuous" spatial resolution by scanning the laser beam across the flame region, then directing this beam onto a single detector. Thus spatial measurements are converted to a temporal series of data. The true spatial resolution is limited only by the beam diameter and width of the sweep. In these experiments the beam is focused to about 1-mm diameter and scans across a region up to 4-cm wide.

Silver, Joel A.↗

Barium Nitrate Raman Laser Development for Remote Sensing of Ozone

In order to understand the impact of anthropogenic emissions upon the earth's environment, scientists require remote sensing techniques which are capable of providing range-resolved measurements of clouds, aerosols, and the concentrations of several chemical constituents of the atmosphere. The differential absorption lidar (DIAL) technique is a very promising method to measure concentration profiles of chemical species such as ozone and water vapor as well as detect the presence of aerosols and clouds. If a suitable DIAL system could be deployed in space, it would provide a global data set of tremendous value. Such systems, however, need to be compact, reliable, and very efficient. In order to measure atmospheric gases with the DIAL technique, the laser transmitter must generate suitable on-line and off-line wavelength pulse pairs. The on-line pulse is resonant with an absorption feature of the species of interest. The off-line pulse is tuned so that it encounters significantly less absorption. The relative backscattered power for the two pulses enables the range-resolved concentration to be computed. Preliminary experiments at NASA LaRC suggested that the solid state Raman shifting material, Ba(NO3)2, could be utilized to produce these pulse pairs. A Raman oscillator pumped at 532 nm by a frequency-doubled Nd:YAG laser can create first Stokes laser output at 563 nm and second Stokes output at 599 nm. With frequency doublers, UV output at 281 nm and 299 nm can be subsequently obtained. This all-solid state system has the potential to be very efficient, compact, and reliable. Raman shifting in Ba(NO3)2, has previously been performed in both the visible and the infrared. The first Raman oscillator in the visible region was investigated in 1986 with the configurations of plane-plane and unstable telescopic resonators. However, most of the recent research has focused on the development of infrared sources for eye-safe lidar applications.

McCray, Christopher L.↗

Real-time tracking and analysis of gas bubble dynamics in laser powder bed fusion using in-situ X-ray characterization and machine learning

Porosity defects remain a significant challenge in the laser powder bed fusion (LPBF) process, adversely affecting the mechanical properties and reliability of additively manufactured components. Here, this study investigates the real-time formation and trajectory of gas bubbles during LPBF of Al6061 alloy using advanced in-situ X-ray characterization and machine learning. The unsupervised Gaussian mixture model and particle tracking algorithm developed are able to precisely track and quantify the properties of gas bubbles and keyhole pores. Our analysis identified five distinct types of gas bubble formation and movement patterns, emphasizing the diverse origins and behaviors of these defects. It enables precise quantification of trajectories, velocities, and morphological changes of gas bubbles, offering a granular view of the subsurface dynamics within the melt pool. Additionally, we explored keyhole-induced pore dynamics, revealing the critical role of keyhole oscillation and collapse for the formation of both large and small gas pores. It defines four different regions of gas bubble movement within the melt pool, providing a clearer understanding of how local fluid dynamics affect pore behavior. The results underscore the importance of integrating in-situ experimental observation and automated machine learning to develop a more robust predictive model for defect formation in LPBF.

In-situ X-ray imaging↗

Laser Processed Condensing Heat Exchanger Technology Development

The reliance on non-permanent coatings in Condensing Heat Exchanger (CHX) designs is a significant technical issue to be solved before long-duration spaceflight can occur. Therefore, high reliability CHXs have been identified by the Evolvable Mars Campaign (EMC) as critical technologies needed to move beyond low earth orbit. The Laser Processed Condensing Heat Exchanger project aims to solve these problems through the use of femtosecond laser processed surfaces, which have unique wetting properties and potentially exhibit anti-microbial growth properties. These surfaces were investigated to identify if they would be suitable candidates for a replacement CHX surface. Among the areas researched in this project include microbial growth testing, siloxane flow testing in which laser processed surfaces were exposed to siloxanes in an air stream, and manufacturability.

Hansen, Scott↗

A vision system for a Mars rover

A Mars rover must be able to sense its local environment with sufficient resolution and accuracy to avoid local obstacles and hazards while moving a significant distance each day. Power efficiency and reliability are extremely important considerations, making stereo correlation an attractive method of range sensing compared to laser scanning, if the computational load and correspondence errors can be handled. Techniques for treatment of these problems, including the use of more than two cameras to reduce correspondence errors and possibly to limit the computational burden of stereo processing, have been tested at JPL. Once a reliable range map is obtained, it must be transformed to a plan view and compared to a stored terrain database, in order to refine the estimated position of the rover and to improve the database. The slope and roughness of each terrain region are computed, which form the basis for a traversability map allowing local path planning. Ongoing research and field testing of such a system is described.

Wilcox, Brian H.↗

A customizable data management framework for high-repetition-rate high-energy-density science

The high-energy-density (HED) physics community is moving toward a new paradigm of high-repetition-rate (HRR) operation. To fully leverage the scientific power of HRR HED facilities, all of the components of each subsystem (laser, targetry, and performance diagnostics) must be connected and synchronized in a reliable and robust manner while the data acquired are tagged and archived in real time. To this end, GA has begun developing a generalized NoSQL-database framework, the MongoDB repository for information and archiving. An organizational strategy has been developed that shifts HED data organization from a shot-based to a diagnostic-based approach in order to increase archival and retrieval efficiency that lends itself to optimization applications. This work is a first step in pushing HRR HED science toward data management solutions that emphasize machine actionability and aim to stimulate community engagement to define data standards in HED science.

Instruments & Instrumentation↗