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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Combining synchrotron X-ray diffraction, mechanistic modeling and machine learning for in situ subsurface temperature quantification during laser melting

Laser melting, such as that encountered during additive manufacturing, produces extreme gradients of temperature in both space and time, which in turn influence microstructural development in the material. Qualification and model validation of the process itself and the resulting material necessitate the ability to characterize these temperature fields. However, well established means to directly probe the material temperature below the surface of an alloy while it is being processed are limited. To address this gap in characterization capabilities, a novel means is presented to extract subsurface temperature-distribution metrics, with uncertainty, from in situ synchrotron X-ray diffraction measurements to provide quantitative temperature evolution data during laser melting. Temperature-distribution metrics are determined using Gaussian process regression supervised machine-learning surrogate models trained with a combination of mechanistic modeling (heat transfer and fluid flow) and X-ray diffraction simulation. The trained surrogate model uncertainties are found to range from 5 to 15% depending on the metric and current temperature. The surrogate models are then applied to experimental data to extract temperature metrics from an Inconel 625 nickel superalloy wall specimen during laser melting. The maximum temperatures of the solid phase in the diffraction volume through melting and cooling are found to reach the solidus temperature as expected, with the mean and minimum temperatures found to be several hundred degrees less. The extracted temperature metrics near melting are determined to be more accurate because of the lower relative levels of mechanical elastic strains. However, uncertainties for temperature metrics during cooling are increased due to the effects of thermomechanical stress.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Tunable Laser-Plasma Amplifier (Final Report)

Exploration at the laser intensity frontier has always offered new avenues for physics and reaching beyond this frontier is a grand challenge. Present-day petawatt-class lasers provide focused intensities on target of 10 22 W/cm 2 , corresponding to electric fields of 200 TV/m, while laser-plasma amplification opens a route for focused intensities well above 10 23 W/cm 2 . Intensities in this range provide the ability to test quantum electrodynamics in the unexplored low-energy, strong-field regime where signatures for new physics may arise. The behavior of matter under such extraordinary conditions is a rich and fascinating subject, not only in its own right in fundamental plasma physics, but for the many potential applications that promise to enrich the natural sciences in the future, including compact electron-beam, ion-beam particle accelerators, and ultra-bright X-ray sources. Although laser systems are now under construction internationally to access intensities of 10 23 W/cm 2 , the current technologies used appear to be fundamentally limited to these intensities. The realization of intensities beyond 10 23 W/cm 2 using parametric amplification in plasmas promises a breakthrough in high-energy density physics. Parametric amplification using Raman scattering in a plasma could provide the enabling technology for the generation of ultra-high-power laser pulses, but a more complete understanding of the nonlinear optics of plasmas is required. There is a significant gap in well-diagnosed laser-plasma instability studies of nonlinear plasma-wave phenomena, which are critical to understand for future laser-plasma devices. To achieve an efficient laser-plasma amplifier, plasma waves must be driven to large amplitude where significant energy can be rapidly transferred from the pump to the seed over the pulse duration of the seed. Simulations suggest that this nonlinear pump depletion regime can be achieved in the “pi-pulse” amplification regime. While simulations show this optimal regime with efficient amplification, it has remained elusive in experiments and there is a growing consensus within the community that thermal effects and pump beam limitations prevent laser-plasma amplifiers from progressing through the linear regime into the nonlinear pump depletion regime. Previous experiments have been significantly limited by the laser power available at the necessary wavelengths for the seed laser; therefore, the amplification is required to start in the linear regime where it is sensitive to many deleterious effects. The enabling technology (currently unique to plasma-wave amplification in the world) at the University of Rochester is the ability to provide a seed pulse with sufficient power (4 mJ/100 fs seed) to immediately drive nonlinear plasma waves into the pi-pulse regime and to tune its wavelength to optimize the efficiency of energy transfer. This in combination with the state-of-the-art OMEGA heater beams providing multiple kilojoules in a nanosecond to sufficiently heat the plasma make this system distinct from previous studies. These heater beams will provide, for the first time in Raman amplification studies, a homogeneous electron temperature high enough to prevent pump beam propagation issues that have plagued previous experiments. These systems will provide a platform for driving electron-plasma waves into the nonlinear regime where pump depletion and pulse shortening are predicted to lead to high amplification efficiencies (>30%). The Team has made significant progress through prior support from DOE Fusion Energy Sciences [DOE Office of Science Award Number DE-SC0016253 (2016-2022)]. This includes twenty-two peer-reviewed manuscripts, one patent, ten contributed talks presented at international conferences, and research that was highlighted as invited talks at fifteen international conferences. The broader impacts of this research are evident in the support of early career scientists, two Ph.D. theses, four current graduate students, a Masters Project, two undergraduate researchers, and an underrepresented minority student hired through the California Alliance for Minority Participation who now works as a Research Engineer in the group. This research met all of the funded research objectives and the highlights from primary Raman amplification thrust of this work are discussed below and form the foundation for the proposed research.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2015

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗
NASA NTRS2010

Mission Simulation of Space Lidar Measurements for Seasonal and Regional CO2 Variations

Results of mission simulation studies are presented for a laser-based atmospheric [82 sounder. The simulations are based on real-time carbon cycle process modeling and data analysis. The mission concept corresponds to the Active Sensing of [82 over Nights, Days, and Seasons (ASCENDS) recommended by the US National Academy of Sciences Decadal Survey of Earth Science and Applications from Space. One prerequisite for meaningful quantitative sensor evaluation is realistic CO2 process modeling across a wide range of scales, i.e., does the model have representative spatial and temporal gradients? Examples of model comparison with data will be shown. Another requirement is a relatively complete description of the atmospheric and surface state, which we have obtained from meteorological data assimilation and satellite measurements from MODIS and [ALIPS0. We use radiative transfer model calculations, an instrument model with representative errors ' and a simple retrieval approach to complete the cycle from "nature" run to "pseudo-data" CO2, Several mission and instrument configuration options are examined/ and the sensitivity to key design variables is shown. We use the simulation framework to demonstrate that within reasonable technological assumptions for the system performance, relatively high measurement precision can be obtained, but errors depend strongly on environmental conditions as well as instrument specifications. Examples are also shown of how the resulting pseudo - measurements might be used to address key carbon cycle science questions.

Kawa, Stephan↗
DOE OSTI2025

Microscale Metal Additive Manufacturing by Solid‐State Impact Bonding of Shaped Thin Films

The deposition of device-grade inorganic materials is one key challenge toward the implementation of additive manufacturing (AM) in microfabrication, and to that end, a broad range of physico-chemical principles has been explored for 3D fabrication with micro- and nanoscale resolution. Yet, for metals, a process that achieves material quality rivalling that of established thin-film deposition methods, and at the same time, has the potential to combine high throughput production with a broad palette of processable materials, is still lacking. Here, the kinetic, solid-state bonding of metal thin films for the additive assembly of high-purity, high-density metals with micrometer-scale precision is introduced. Indirect laser ablation accelerates micrometer-thick gold films to hundreds of meters per second without their heating or ablation. Their subsequent impact on the substrate above a critical velocity forms a permanent, metallic bond in the solid state. Stacked layers are of high density (>99%). By defining thin-film layers with established lithographic methods prior to launch, a variable feature size (2–50 µm), arbitrary shape of bonded layers, and parallel transfer of up to 36 independent film units in a single shot, is demonstrated. Thus, the solid-state kinetic bonding principle as a viable and potentially versatile route for micro-scale AM of metals is established.

3D printing↗
DOE OSTI2022

Optimization of Backscatter and Symmetry for Laser Fusion Experiments Using Multiple Tunable Wavelengths

A new additional wavelength-tuning capability has been implemented on the National Ignition Facility (NIF) laser allowing for unprecedented control of crossed-beam energy transfer (CBET) between all groups of beams for better performance of indirect-drive inertial confinement fusion (ICF) ignition experiments. In particular, this advance allows for negation and reversal of flow-induced CBET and the rebalancing of the intensity of different groups of beams within an indirect-drive (ICF) hohlraum. The experiments conducted at the NIF using a 1.1 MJ laser pulse with peak power of 390 TW demonstrate this high level of control through measurements of the precise changes to stimulated Brillouin scattering, typically driven by flow-induced CBET at the end of the pulse. Additionally, this new capability is shown to be able to predictably control gold-wall plasma expansion in the target driven by early-time flow-induced CBET. Estimates of early-time CBET from the wall expansion are shown to be consistent with simulation expectations. This new additional capability to control symmetry and backscatter expands the design space of current experiments and provides extra margin for increased laser energy in near-future experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2024

ECI Final Report: Closing of Critical Technology Gaps for Rotating Detonation Rocket Engines

NASA has successfully fired several configurations of a dual regenerative 10K lbf class Rotating Detonation Rocket Engines using cryogenic liquid methane, liquid hydrogen, and RP-1 as fuel and liquid or gaseous oxygen as the oxidizer. In addition, 3 hot fire test phases were conducted to evaluate parametrically varying combustor geometries using a subscale 500-1K lbf class thruster RDRE. Several studies were successfully completed to evaluate the impacts of contraction ratio, annulus L’, heat transfer through calorimetry, and varying injector designs. Laser powder bed fusion GRCop-42, GRX-810, and C-103 alloys were used for the outer bodies, inner bodies, nozzles, and injector variations. The development of RDRE technology is only now possible with additive manufacturing techniques and these specialized alloys. Critical design parameters, design rules of thumb, and operability limitations have been identified. Major lessons learned in the development of critical components have also been documented. All critical technology gaps have been demonstrated at one scale or another and closed. A major finding of this work is that the combustion efficiency of the RDRE is far superior to that of the traditional liquid rocket engine requiring an order of magnitude lower chamber volume and residence time to react. Because of this, the design trade space opens up significantly. More compact chamber geometries are now possible with potential mass savings and significant length savings possible to flight geometries. In addition, the ceiling for the technology, in terms of Isp, has not yet been reached. It is likely that an additional ~10% better Isp over equivalent state-of-the-art combustion devices may be achieved over the next decade should the technology continue to be developed. This technology has been shown to be viable for near term infusion (2-5 years) into space missions and enable cost effective space access for US industry. This final report documents all major findings from this early career initiative (ECI) project and lays out what is needed post ECI.

Thomas Teasley↗
DOE OSTI2025

Inkless, dry printing nanographene via in-Situ Coordinated laser ablation and sintering processes

Printing carbon, such as graphene and other carbon structures, for flexible and printed electronics currently relies on either ink-based printing, laser-induced forward transfer (LIFT), or laser-induced graphitization (LIG) to convert carbon-rich precursor materials, such as polymers, to graphene-like carbon structures. Liquid inks contain toxic solvents, surfactants, and stabilizing additives that degrade electrical conductivity and require high-temperature post-processing. On the other hand, LIG is limited by the substrate. Here, this study introduces an additive manufacturing method for dry-printing carbon nanomaterials, ranging from amorphous carbon to crystalline graphene-like structures, on various substrates. The system utilizes laser ablation of a solid graphite target to create pure carbon nanoparticles in situ and on demand. An inert gas carries the nanoparticles onto the substrate, where they can be deposited either as amorphous structures or laser-sintered in real time to form various graphitic structures. The study of laser processing parameters, specifically fluence and pulse repetition frequency, revealed three unique regimes of nanostructure evolution that influence the morphological and electrical properties of these printed structures. Raman spectroscopy confirmed graphitization with a resistivity slightly higher than that of the bulk graphite target. The conductivity/resistivity could be tuned as a function of sintering laser power. Scanning transmission electron microscopy (STEM) revealed that turbostratic nanographene formed with an interlayer spacing of 0.40 nm. Despite ink-based printing methods, such as screen printing, inkjet printing (IJP), and aerosol jet printing (AJP), this eco-friendly and green manufacturing technique could eliminate toxic chemicals, reduce environmental impact, and enable single-step fabrication of carbon-based devices for applications in wearable sensors, energy storage, flexible electronics, and Internet of Things (IoT) devices.

Additive nanomanufacturing↗
DOE OSTI2021

Mechanism and dynamics of fatty acid photodecarboxylase

Photoenzymes are rare biocatalysts driven by absorption of a photon at each catalytic cycle; they inspire development of artificial photoenzymes with valuable activities. Fatty acid photodecarboxylase (FAP) is a natural photoenzyme that has potential applications in the bio-based production of hydrocarbons, yet its mechanism is far from fully understood. RATIONALE To elucidate the mechanism of FAP, we studied the wild-type (WT) enzyme from Chlorella variabilis (CvFAP) and variants with altered active-site residues using a wealth of techniques, including static and time-resolved crystallography and spectroscopy, as well as biochemical and computational approaches. RESULTS A 1.8-Å-resolution CvFAP x-ray crystal structure revealed a dense hydrogen-bonding network positioning the fatty acid carboxyl group in the vicinity of the flavin adenine dinucleotide (FAD) cofactor. Structures solved from free electron laser and low-dose synchrotron x-ray crystal data further highlighted an unusual bent shape of the oxidized flavin chromophore, and showed that the bending angle (14°) did not change upon photon absorption (step 1) or throughout the photocycle. Calculations showed that bending substantially affected the energy levels of the flavin. Structural and spectroscopic analysis of WT and mutant proteins targeting two conserved active-site residues, R451 and C432, demonstrated that both residues were crucial for proper positioning of the substrate and water molecules and for oxidation of the fatty acid carboxylate by 1 FAD* (~300 ps in WT FAP) to form FAD ∙– (step 2). Time-resolved infrared spectroscopy demonstrated that decarboxylation occured quasi-instantaneously upon this forward electron transfer, consistent with barrierless bond cleavage predicted by quantum chemistry calculations and with snapshots obtained by time-resolved crystallography. Transient absorption spectroscopy in H 2 O and D 2 O buffers indicated that back electron transfer from FAD ∙– was coupled to and limited by transfer of an exchangeable proton or hydrogen atom (step 3). Unexpectedly, concomitant with FAD ∙– reoxidation (to a red-shifted form FAD RS ) in 100 ns, most of the CO 2 product was converted, most likely into bicarbonate (as inferred from FTIR spectra of the cryotrapped FAD RS intermediate). Calculations indicated that this catalytic transformation involved an active-site water molecule. Cryo-Fourier transform infrared spectroscopy studies suggested that bicarbonate formation (step 4) was preceded by deprotonation of an arginine residue (step 3). At room temperature, the remaining CO 2 left the protein in 1.5 μs (step 4'). The observation of residual electron density close to C432 in electron density maps derived from time-resolved and cryocrystallography data suggests that this residue may play a role in stabilizing CO 2 and/or bicarbonate. Three routes for alkane formation were identified by quantum chemistry calculations; the one shown in the figure is favored by the ensemble of experimental data. CONCLUSION Finally, we provide a detailed and comprehensive characterization of light-driven hydrocarbon formation by FAP, which uses a remarkably complex mechanism including unique catalytic steps. We anticipate that our results will help to expand the green chemistry toolkit.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1980

A microprocessor application to a strapdown laser gyro navigator

The replacement of analog circuit control loops for laser gyros (path length control, cross axis temperature compensation loops, dither servo and current regulators) with digital filters residing in microcomputers is addressed. In addition to the control loops, a discussion is given on applying the microprocessor hardware to compensation for coning and skulling motion where simple algorithms are processed at high speeds to compensate component output data (digital pulses) for linear and angular vibration motions. Highlights are given on the methodology and system approaches used in replacing differential equations describing the analog system in terms of the mechanized difference equations of the microprocessor. Standard one for one frequency domain techniques are employed in replacing analog transfer functions by their transform counterparts. Direct digital design techniques are also discussed along with their associated benefits. Time and memory loading analyses are also summarized, as well as signal and microprocessor architecture. Trade offs in algorithm, mechanization, time/memory loading, accuracy, and microprocessor architecture are also given.

Giardina, C.↗
NASA NTRS1989

Advanced Solar-propelled Cargo Spacecraft for Mars Missions

Three concepts for an unmanned, solar powered, cargo spacecraft for Mars support missions were investigated. These spacecraft are designed to carry a 50,000 kg payload from a low Earth orbit to a low Mars orbit. Each design uses a distinctly different propulsion system: A Solar Radiation Absorption (SRA) system, a Solar-Pumped Laser (SPL) system and a solar powered magnetoplasmadynamic (MPD) arc system. The SRA directly converts solar energy to thermal energy in the propellant through a novel process. In the SPL system, a pair of solar-pumped, multi-megawatt, CO2 lasers in sunsynchronous Earth orbit converts solar energy to laser energy. The MPD system used indium phosphide solar cells to convert sunlight to electricity, which powers the propulsion system. Various orbital transfer options are examined for these concepts. In the SRA system, the mother ship transfers the payload into a very high Earth orbit and a small auxiliary propulsion system boosts the payload into a Hohmann transfer to Mars. The SPL spacecraft and the SPL powered spacecraft return to Earth for subsequent missions. The MPD propelled spacecraft, however, remains at Mars as an orbiting space station. A patched conic approximation was used to determine a heliocentric interplanetary transfer orbit for the MPD propelled spacecraft. All three solar-powered spacecraft use an aerobrake procedure to place the payload into a low Mars parking orbit. The payload delivery times range from 160 days to 873 days (2.39 years).

Auziasdeturenne, Jacqueline↗
DOE OSTI2020

Tailoring Surface Roughness Using Additive Manufacturing to Improve Internal Cooling

Abstract Surface roughness present on internal cooling channels produced with additive manufacturing has been previously shown to augment heat transfer and pressure loss to levels similar to traditionally cast turbulators. Given the ability of the surface roughness to improve the cooling performance of small cooling channels, the question arises on whether there is an optimal combination of random roughness features to maximize internal cooling performance. To investigate this question, test coupons with different surface roughness morphologies and magnitudes were manufactured by manipulating the parameters in the laser powder bed fusion additive manufacturing process. The coupons were tested to characterize the friction factor and Nusselt number of the cooling channels over a range of Reynolds numbers. Results showed that certain roughness combinations outperformed others, increasing the internal cooling performance of the channels. Additionally, manipulation of the performance using the process parameters allowed for reductions in build time, which could be useful for controlling component cost.

Engineering↗
DOE OSTI2020

Carbon ablator areal density at fusion burn: Observations and trends at the National Ignition Facility

For inertial confinement fusion experiments, the pusher is composed of a high-density deuterium tritium cyrogenic fuel layer and an ablator, often made of carbon. In an ideal, no-mix implosion, increasing the areal density of the pusher transfers more pressure to the hot spot and increases the hot spot confinement time. There has been a lack of knowledge about the final compressed state of the ablator for implosions at the National Ignition Facility. 14 MeV fusion neutrons inelastically scattering on the remaining carbon ablator excites a nuclear metastable state that emits a prompt 4.4 MeV gamma ray. The gamma reaction history diagnostic data, when reduced by a new data analysis technique, can isolate and measure the carbon gamma rays, which are proportional to the areal density of the ablator during fusion burn. The trends over many National Ignition Facility campaigns show that the ablator areal density is weakly sensitive to the maximum shell velocity, the cold fuel radius, the ablator mass remaining, or the laser picket intensity. Controlled parameter scans reveal that, for specific campaigns, ablator compression has a strong dependence on laser coast time, high Z dopants, and the laser drive foot duration. Using a model of the compressed ablator density profile reveals that the greatest variation of the ablator areal density comes from its thickness, with highly compressed, thin layers having high areal density values. The compression and thickness of the ablator are other metrics that designers should understand to differentiate the types of capsule degradation and maximize the inertial confinement fusion performance.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1992

LV software support for supersonic flow analysis

The software for configuring a Laser Velocimeter (LV) counter processor system was developed using structured design. The LV system includes up to three counter processors and a rotary encoder. The software for configuring and testing the LV system was developed, tested, and included in an overall software package for data acquisition, analysis, and reduction. Error handling routines respond to both operator and instrument errors which often arise in the course of measuring complex, high-speed flows. The use of networking capabilities greatly facilitates the software development process by allowing software development and testing from a remote site. In addition, high-speed transfers allow graphics files or commands to provide viewing of the data from a remote site. Further advances in data analysis require corresponding advances in procedures for statistical and time series analysis of nonuniformly sampled data.

Bell, William A.↗
NASA NTRS1980

Design considerations for optical heterodyne receivers: A review

The current state of knowledge concerning optical heterodyne receivers is reviewed. Following a discussion of noise processes in the heterodyne receiver and the manner in which sensitivity is increased through time integration of the detected signal, an expression for the mean square signal current is derived by mixing a coherent local oscillator with a partially coherent, quasimonochromatic source. Then the manner in which the IF signal calculation can be transferred to any convenient plane in the optical front end of the receiver is demonstrated. Using these techniques, a relatively simple equation is obtained for the coherently detected signal from an extended incoherent source and applied to the heterodyne detection of an extended thermal source and to the backscatter lidar problem where the antenna patterns of both the transmitter beam and heterodyne receiver must be taken into account. Finally, the detection of a coherent source is considered and, in particular, a distant point source such as a star or laser transmitter in a long range heterodyne communications system is discussed.

Degnan, J. J.↗
DOE OSTI2025

Spatially and temporally resolved plasma parameter estimations of laser heated MagLIF relevant gas pipes at NIF

The ability to control laser pre-heat is an integral part of the inertial confinement fusion concept known as Magnetized Liner Inertial Fusion. This process is studied at the National Ignition Facility (NIF) where 4 of the 192 laser beams are propagated through a 1-cm long gas cell where they deposit >20 kJ of energy into the gaseous fuel via inverse bremsstrahlung absorption. This process ionizes the gas, producing a plasma that follows behind the laser front and expands over the radius of the cell. Emission from this plasma, as viewed by a gated x-ray detector, can be used to build spatially and temporally resolved estimations of the pre-heat plasma's density and temperature profiles. This can then be used to estimate the plasma pressure, internal energy, and radiation losses. Estimations show the evolution of the plasma in magnetized and unmagnetized gas cells filled with ambient temperature neopentane (C5H12) +1% Ar, as well as unmagnetized cryogenically cooled (32 K) deuterium +1% Ne filled targets. This analysis shows the effects of initial gas-fill density, composition, and axial magnetization on the time-dependent plasma parameters. Previously, these parameters at the NIF had not been experimentally characterized, and these estimations provided a potential new means of testing radiation magneto-hydrodynamic predictive capability models. Results in unmagnetized targets have strong agreement with simulations. However, in targets with a 19 T applied axial magnetic field, this method yields electron temperatures up to 100% hotter than those predicted by HYDRA codes.

Bremsstrahlung↗
NASA NTRS1999

Experimental Investigation of Pool Boiling Heat Transfer Enhancement in Microgravity in the Presence of Electric Fields

In boiling high heat fluxes are possible driven by relatively small temperature differences, which make its use increasingly attractive in aerospace applications. The objective of the research is to develop ways to overcome specific problems associated with boiling in the low gravity environment by substituting the buoyancy force with the electric force to enhance bubble removal from the heated surface. Previous studies indicate that in terrestrial applications nucleate boiling heat transfer can be increased by a factor of 50, as compared to values obtained for the same system without electric fields. The goal of our research is to experimentally explore the mechanisms responsible for EHD heat transfer enhancement in boiling in low gravity conditions, by visualizing the temperature distributions in the vicinity of the heated surface and around the bubble during boiling using real-time holographic interferometry (HI) combined with high-speed cinematography. In the first phase of the project the influence of the electric field on a single bubble is investigated. Pool boiling is simulated by injecting a single bubble through a nozzle into the subcooled liquid or into the thermal boundary layer developed along the flat heater surface. Since the exact location of bubble formation is known, the optical equipment can be aligned and focused accurately, which is an essential requirement for precision measurements of bubble shape, size and deformation, as well as the visualization of temperature fields by HI. The size of the bubble and the frequency of bubble departure can be controlled by suitable selection of nozzle diameter and mass flow rate of vapor. In this approach effects due to the presence of the electric field can be separated from effects caused by the temperature gradients in the thermal boundary layer. The influence of the thermal boundary layer can be investigated after activating the heater at a later stage of the research. For the visualization experiments a test cell was developed. All four vertical walls of the test cell are transparent, and they allow transillumination with laser light for visualization experiments by HI. The bottom electrode is a copper cylinder, which is electrically grounded. The copper block is heated with a resistive heater and it is equipped with 6 thermocouples that provide reference temperatures for the measurements with HI. The top electrode is a mesh electrode. Bubbles are injected with a syringe into the test cell through the bottom electrode. The working fluids presently used in the interferometric visualization experiments, water and PF 5052, satisfy requirements regarding thermophysical, optical and electrical properties. A 30kV power supply equipped with a voltmeter allows to apply the electric field to the electrodes during the experiments. The magnitude of the applied voltage can be adjusted either manually or through the LabVIEW data acquisition and control system connected to a PC. Temperatures of the heated block are recorded using type-T thermocouples, whose output is read by a data acquisition system. Images of the bubbles are recorded with 35mm photographic and 16mm high-speed cameras, scanned and analyzed using various software packages. Visualized temperature fields HI allows the visualization of temperature fields in the vicinity of bubbles during boiling in the form of fringes. Typical visualized temperature distributions around the air bubbles injected into the thermal boundary layer in PF5052 are shown. The temperature of the heated surface is 35 C. The temperature difference for a pair of fringes is approximately 0.05 C. The heat flux applied to the bottom surface is moderate, and the fringe patterns are regular. In the image a bubble penetrating the thermal boundary layer is visible. Because of the axial symmetry of the problem, simplified reconstruction techniques can be applied to recover the temperature field. The thermal plume developing above the heated surface for more intensive heating is shown. The temperature distribution in the liquid is clearly 3D, and tomographic techniques have to be applied to recover the temperature distribution in such a physical situation. A sequence of interferometric images showing the temperature distribution around the rising bubble, recorded with a high-speed camera is shown. Again, the temperature distribution is 3D, and a more complex approach to the evaluation, the tomographic reconstruction has to be taken. Measurement of the temperature distribution from the fringe pattern temperature distributions that yield important information regarding heat transfer are determined. Two algorithms that allow the quantitative evaluation of interferometric fringe patterns and the reconstruction of temperature fields during boiling have been developed at the Heat Transfer Laboratory of the Johns Hopkins University. In the first algorithm the bubble is assumed to be axially symmetrical, which significantly reduces the computational effort for quantifying the temperature distribution around the bubble. For this purpose the thermal boundary layer around the bubble is divided into equidistant concentric shells, and the refractive index is assumed to be constant in each of the shells. Since large temperature gradients are expected in the vicinity of the bubble during boiling, the deflection of the light beam cannot be neglected in boiling experiments. Since the exit angle of the light beam is known, this allows to account for the deflections and phase shifts outside the boundary layer (in the bulk fluid and in the windows of the test cell). Three dimensional temperature distributions in the vicinity of the bubble are reconstructed using tomographic techniques. In tomography, the measurement volume is sliced into 2D planes. In the present study these planes are parallel to the heated surface. The objective is to determine the values of the field parameter of interest in form of the field function in these 2D planes. The field parameter is the change of the refractive index of the liquid in the measurement volume caused by temperature changes. By superimposing data for many 2D planes recorded at the same time instant, the 3D temperature distribution in the measurement volume is recovered.

Herman, Cila↗
DOE OSTI2020

Process optimization of complex geometries using feed forward control for laser powder bed fusion additive manufacturing

Additive manufacturing (AM) enables the fabrication of complex designs that are difficult to create by other means. Metal parts manufactured by laser powder bed fusion (LPBF) can incorporate intricate design features and demonstrate desirable mechanical properties. However, printing a part that is qualified for its intended application often involves reprinting and discarding many parts to eliminate defects, improve dimensional accuracy, and increase repeatability. The process of iteratively converging on the appropriate build parameters increases the time and cost of creating functional LPBF manufactured parts. This work describes a fast, scalable method for part-scale process optimization of arbitrary geometries. Additionally, the computational approach uses feature extraction to identify scan vectors in need of parameter adaptation and applies results from simulation-based feed forward control models. This method provides a framework to quickly optimize complex parts through the targeted application of models with a range of fidelity and by automating the transfer of optimization strategies to new part designs. The computational approach and algorithmic framework are described, a software package is implemented, the method is applied to parts with complex features, and parts are printed on a customized open architecture LPBF machine.

3D printing↗