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Results for “laser beam machining”

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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Plutonium oxide melt structure and covalency

Advances in nuclear power reactors include the use of mixed oxide fuel, containing uranium and plutonium oxides. The high-temperature behaviour and structure of PuO 2-x above 1,800 K remain largely unexplored, and these conditions must be considered for reactor design and planning for the mitigation of severe accidents. Here, in this study, we measure the atomic structure of PuO 2-x through the melting transition up to 3,000 +/- 50 K using X-ray scattering of aerodynamically levitated and laser-beam-heated samples, with O/Pu ranging from 1.57 to 1.76. Liquid structural models consistent with the X-ray data are developed using machine-learned interatomic potentials and density functional theory. Molten PuO 1.76 contains some degree of covalent Pu-O bonding, signalled by the degeneracy of Pu 5f and O 2p orbitals. The liquid is isomorphous with molten CeO 1.75 , demonstrating the latter as a non-radioactive, non-toxic, structural surrogate when differences in the oxidation potentials of Pu and Ce are accounted for. These characterizations provide essential constraints for modelling pertinent to reactor safety design. The molten structure of plutonium oxide-a component of mixed oxide nuclear fuels-is measured, showing some degree of covalent bonding. Its atomic structure is similar to that of cerium oxide, which could be a non-radioactive structural surrogate.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Comparison of three measurement modalities for 3D characterization of manufactured features and process-induced porosity in titanium alloy additively manufactured parts

Nondestructive characterization of internal features and defects within complex components is vital for many industrial applications, particularly with the advent of additive manufacturing (AM) technologies. However, community understanding of the limitations of nondestructive methods such as X-ray Computed Tomography (CT) can be limited in certain industrial sectors as these may be emergent applications. In this paper, we investigate the limits of X-ray CT measurements and compare extracted data with mechanical polishing serial sectioning (MPSS) and confocal laser scanning microscopy (CLSM). The test object is an additively manufactured titanium alloy disk that contains both process-induced porosity and machined features, including focused ion beam milled features designed to probe the resolution limits of X-ray CT. Results show that each of these characterization techniques has advantages and disadvantages. We compare data acquisition times, spatial resolution, geometric measurement accuracy and defect visualization fidelity across these modalities to establish a practical framework.

Additive manufacturing↗
DOE OSTI2024

Study on ion current density of different species in laser produced plasma in a solenoid magnet

A solenoid magnetic field along the expanding laser-produced plasma is an essential technique of the laser ion source. The solenoid field can increase ion beam current at beam extraction point by a factor of 2 to over 100 by confining moving laser produced plasma in transverse direction. This technique is used everywhere from development lab to operational machine for user operation. However, the motion of ions in laser produced plasma is not fully understood. In this study, we experimentally investigated the motion of ions in a solenoid magnet (inner diameter 102 mm, coil length 1980 mm) for Al, Fe, and Ta targets. Using the following three conditions: full solenoid bore, a φ51 mm collimator on the solenoid axis, and a thin-wall φ51 mm tube at the bottom of the solenoid, we found that extracting ions at off-axis position (20~30 mm from the solenoid axis in this study) can enhance ion intensity by a factor of three or more. We continue to investigate ion motion in a solenoid field to develop better laser ion source design.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Assessment of Additive Manufacturing of Particle Accelerator [Slides]

Metal additive manufacturing of copper components has been commercialized on multiple printing modalities; including Bound Metal Deposition (BMD), Laser Powder Bed Fusion (LPBF), and Electron Beam Melting (EBM). BMD was selected at the primary printing modality for this TED because of the availability of the Markforged Metal X machine within the LANL E-2 AM research lab. Linear accelerator (LINAC) structures are similarly demonstrated technology. Accelerator structures are typically made of high purity oxygen-free electronic copper owing to the material’s high electrical and thermal conductivity. Conventionally machined and brazed, welded, or bolted designs are difficult to manufacture and require long lead times.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Fielding and analyzing performance of a prototype high voltage output gas switch for Saturn

Timing spread between the thirty-six Saturn modules affects peak electrical power delivered to the Bremsstrahlung diode and can affect vacuum power flow and impedance behavior of the load. To reduce the module spread, a new megavolt gas-insulated closing switch was developed employing design techniques developed for the Z-machine laser triggered switches while retaining Saturn’s simpler electrical triggering. Two modules were temporarily outfitted with the new switches and used separately into local resistive loads (instead of the usual Saturn electron beam load). A reliable operating point and switch time jitter at that point were the goals of the experiments. The target switch reliability is less than one pre-fire in one thousand switch-shots, and a timing standard deviation of 4 nanoseconds. The switches were able to meet both requirements but the number of tests at the chosen point are limited.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Probing local electron temperature and density inside a sheared flow stabilized Z-pinch using portable optical Thomson scattering

We report the first optical Thomson scattering measurements inside a high electron temperature (≳1 keV) and moderate electron density (mid 10 16 cm –3 ) plasma. This diagnostic has been built to provide critical plasma parameters, such as electron temperature and density, for Advanced Research Projects Agency-Energy-supported fusion-energy concepts. It uses an 8 J laser at 532 nm in 1.5 ns to measure the high frequency feature of the Thomson scattering profile at 17 locations along the probe axis. It is able to measure electron density from 5 × 10 17 cm –3 to several 10 19 cm –3 and electron temperatures from tens of eV to several keV. Here, in this paper, we describe the design, deployment, and analysis on the sheared flow stabilized Z-pinch machine at Zap Energy named FuZE. The probe beam is aimed at an axial distance of 20 cm from the central electrode and is timed within the temporal envelope of neutron emission. The high temperature and moderate density plasmas generated on FuZE lie in an unconventional regime for Thomson scattering as they are between tokamaks and laser-produced plasmas. We described the analysis considerations in this regime, show that the electron density was below 5 × 10 16 cm –3 at all times during these measurements, and present a sample shot where the inferred electron temperature varied from 167 ± 16 eV to 700 ± 85 eV over 1.6 cm.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

The design of a line velocity interferometer for any reflector for inertial confinement experiments on the Z-machine

A line VISAR (Velocity Interferometer System for Any Reflector) has been designed and commissioned at the Sandia National Laboratory’s Z-machine. The instrument consists of an F/2 collection system, beam transport, and an interferometer table that contains two Mach–Zehnder type interferometers and an eight channel Gated Optical Imaging (GOI) system. The VISAR probe laser operates at the 532 nm wavelength, and the GOI bandpass is 540–600 nm. The output of each interferometer is passed to an optical streak camera with four selectable sweep speeds. The system is designed with three interchangeable optics modules to select a full field of view of 1 mm, 2 mm, or 4 mm. The optical beam transport system connects the target image plane to the interferometers and the gated optical imagers. The target is integrated into a sacrificial final optics assembly that is integral to the transport beamline.

Datte, P.↗
DOE OSTI2026

Automation of Laser Plasma Focused Ion Beam Microscopy for Next-Gen Energy Materials

Automation can revolutionize the use of ultrafast laser ablation and plasma-focused ion beam (PFIB) techniques for high-throughput, reproducible cross-sectioning and various sample preparation in materials characterization. As these methods become essential for analyzing complex energy materials and next-generation devices, efficient, standardized workflows are needed to minimize variability and enhance precision. This work highlights our advancements in developing automated processes for sample preparation that integrates machine learning, workflow optimization, and large-scale data acquisition to improve efficiency and scalability in applications such as electrolyzers, photovoltaic cells, and microelectronics. To streamline cross-sectioning and lamella fabrication, we have implemented fully automated workflows that standardize laser ablation and PFIB milling sequences. These workflows incorporate pre-programmed protocols for material removal, alignment, and thinning, reducing user intervention and ensuring consistency across different sample types. Machine learning algorithms further enhance automation by predicting optimal milling strategies and adapting parameters based on material properties and sectioning requirements. This approach significantly improves throughput while maintaining the structural integrity of prepared samples for high-resolution imaging and analysis, including transmission electron microscopy. Beyond sample preparation, our automation platform enables the acquisition of large, high-resolution datasets through serial sectioning, image alignment, and 3D reconstruction. These automated routines facilitate multi-scale characterization, capturing structural and compositional details from the nanoscale to the device level. By reducing variability and increasing efficiency, our automated approach enhances defect analysis, failure diagnostics, and process optimization, accelerating advancements in materials research and device engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Machine Learning Pattern Recognition Algorithm With Applications to Coherent Laser Combination

Herein we analyze a new kind of machine learning algorithm designed to feedback stabilize coherently combined lasers. This algorithm learns differential, rather than absolute, values of action in phase space, in order to facilitate learning on initially unstable systems. Experiments have shown that this approach can control small-scale spatial beam combination with high stability. In this paper we analyze the algorithm's performance and limitations in depth, showing that it can continuously learn during operation in order to track changes. Using simulation, we extend the application to temporal combination, and show that it scales to more complex instances by combining 81 beams.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Stability of zirconium hydride

This reports complete Milestone M2.2.1 Stability of zirconium hydride: Experimental investigation of the hydrogen concentration of encapsulated zirconium hydride before and after joining. In this milestone, we first report the successful fabrication of crack-free bulk zirconium hydride by using the ORNL static hydriding system. The fabricated hydride was characterized by using X-ray diffraction (XRD) and X-ray computed tomography (XCT). XRD results showed that the δ-phase zirconium hydride, α-zirconium, and ε-phase hydride were present. XCT confirmed the absence of the internal cracking. The hydrogen concentration was determined by the weight change before and after hydrogen loading, given the fact that the oxide phase was not found during XRD analysis. Two metallic cladding materials, i.e., molybdenum and FeCrAl, were selected to encapsulate the fabricated zirconium hydride pellets. Demonstration capsules were designed and machined. Mo crucible was successfully sealed by using a combination of electron beam welding and gas tungsten arc welding. Due to the undesired neutronics property of Mo, further investigation of this cladding material was not pursued. Electron beam welding and laser beam welding were employed to seal the FeCrAl capsules. XRD were performed on the zirconium hydride before and after the sealing. The results showed that the welding process has negligible impact on the hydrogen content in the FeCrAl-canned zirconium hydride. The presented work fulfilled the proposed work under this milestone and paves a pathway to fabricate single-phase zirconium hydride and to develop robust cladding materials to can bulk zirconium hydride.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Three-dimensional simulation of the University of Hawai‘i FEL oscillator with cavity desynchronization

In this paper, we present three-dimensional, time-dependent simulations of the University of Hawai‘i (UH) at Mānoa free-electron laser (FEL) oscillator. Using beam parameters from the UH facility, we study the pass-by-pass evolution of the radiation field, including its temporal, spectral, and transverse properties. At nominal bunch length, the radiation pulse develops temporal spiking near saturation, together with sideband formation and increased sensitivity to machine timing jitter. Our results show that modest cavity desynchronization can enhance the radiation energy by 63%. Large cavity desynchronization, on the other hand, can effectively suppress the spiking instabilities and improve robustness to timing fluctuations. Finally, we simulate a short-bunch operational mode with a bunch length comparable to the slippage length, which accelerates saturation and further amplifies the FEL power. Overall, these results provide a quantitative foundation for pulse control studies in the UH FEL oscillator and a critical benchmark for future experimental validation and machine optimization.

free-electron lasers↗
DOE OSTI2021

Atomic understanding of structural deformations upon ablation of graphene

We investigate the atomic rearrangement in graphene under femtosecond pulse illumination with reactive molecular dynamics simulations and compare with ultra-fast laser ablation experiments. To model the impact of the laser pulse irradiation, heat is locally applied to a selected area of the graphene layer and the resulting structural deformation is simulated as a function of time, providing a detailed understanding of the bond breaking process under laser illumination and subsequent re-equilibration afterAQ3 the pulse is turned off. Analysis of the atomic dynamics indicates that the types of defects formed depend on the pulse energy and exposure duration. By varying the exposed area, we determine that the shape of the ablated area is not only a function of the pulse energy, but also of the beam spot size and pulse repetition. Furthermore, we apply a machine learning approach to extrapolate our simulated data to experimental length scales and reproduce the trends in ablated area as a function of temperature. Furthermore, our study provides a first step towards understanding the design parameters for graphene nano-patterning.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2023

Post-Shot Report for OMEGA Double Cylinders (CylDRT 22B)

The direct-drive double cylinder experimental platform is a high-energy-density (HED) science platform designed to image an imploding cylindrical target. The target consists of a directly-driven outer cylinder and a shock-and-collision driven inner cylinder. The purpose of this platform is to study hydrodynamic instability growth on the inner cylinder, the outer surface of which is classically Rayleigh-Taylor unstable during the acceleration phase. We present results from recent experiments at the OMEGA laser facility. These experiments were designed as a proof-of-principle for the platform, using the same cylinder exterior dimensions and direct-drive beam configuration as previous single cylinder experiments. In these experiments, three sets of targets were fielded: no machined perturbations (smooth), a sinusoidal mode-10 perturbation on the outer surface of the inner cylinder, and a mode-20 perturbation on the outer surface of the inner cylinder. The primary diagnostic was a gated x-ray framing camera which imaged the backlit inner cylinder on-axis for sixteen frames over a time window of 1 ns for each shot. A second side-lit radiograph captured one image per shot, diagnosing axial uniformity. In this report we include an overview of the results from both the backlighter and the sidelighter diagnostics. We discuss at length the experimental analysis process. Finally, we present the results of the smooth target implosion trajectory and compare them to post-shot simulations. We see favorable agreement between simulation and experiment.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Power Density Distributions in Electron Beams

Measuring and controlling the power density distribution of electron beams used for welding is critical for producing repeatable welds and for transferring welding parameters between different machines. On any given machine, the power density distribution is controlled by defocusing the beam relative to its sharpest focused condition. However, measuring the power density distribution can be difficult due to the intense nature of welding beams and is further complicated by imperfect electron optics that can distort the beam, making it difficult to quantify. The enhanced modified Faraday cup (EMFC) diagnostic method was used here for beam analysis that utilizes computed tomography to reconstruct the beam’s power density distribution. These results were compared to the International Standards Organization (ISO) method for characterizing laser beams using a second-moment D4σ calculation. For ideal Gaussian-shaped beams, both methods would give the same result. However, for imperfect beams, the calculated D4σ diameter was shown to be about 25% larger relative to the FWe2 diameter measured by the EMFC due to the heavier weighting of data in the tails of the beam by D4σ. Finally, although both methods produce repeatable welds, it is important to understand the differences in the reported beam diameters, divergence angles, and beam parameter products when transferring parameters between machines.

36 MATERIALS SCIENCE↗
DOE OSTI2024

EXPLORING INTERFEROMETRY DIAGNOSTICS FOR OPTICAL STOCHASTIC COOLING AT FAST/IOTA

Optical Stochastic Cooling (OSC) is an advanced beam-cooling technique that will advance the traditional stochastic cooling. This method leverages optical radiation and high-precision feedback to cool the particles more efficiently than traditional stochastic methods by more than three orders of magnitude. As such, it is an enabler for the development of next generation discovery science machines at the frontiers of energy and intensity. This paper focuses on the development of the second phase of OSC and improving extreme beam cooling techniques in accelerators. The goal was to build and characterize a Mach-Zehnder Interferometer (MZI) in the FAST laser lab using known glass plates thickness which will allow future measurements of unknown phase change due to nonlinear amplification processes.

Teriba, Folashade↗
DOE OSTI2024

Very high cycle fatigue characteristics of laser beam powder bed fused AlSi10Mg: A systematic evaluation of part geometry

This study explores the influence of geometry and part size on defect distribution, melt pool size, and mechanical characteristics in laser beam powder bed fused (LB-PBF) AlSi10Mg. Five distinct geometries—hourglass, small rod, small block, large block, and large rod—were fabricated under identical process parameters. Fully reversed ultrasonic fatigue testing, operating at a frequency of 20 kHz, was conducted to assess the very high cycle fatigue properties. The findings indicated that part geometry had a major impact on the fatigue properties of the material in the very high cycle fatigue regime. Specimens machined from large rods and large blocks had the lowest porosity and highest fatigue resistance. Microstructural analysis indicated that hourglass, small rod, and small block specimens had shallower melt pools and overlap depths compared to other geometries. This observation suggests a higher cooling rate in specimens with smaller cross-sectional areas, leading to the increased presence of entrapped gas pores and a lack of fusion defects. Understanding the relationship between part geometry and fatigue properties in LB-PBF components offers insights for optimizing design and manufacturing processes in additive manufacturing applications.

AlSi10Mg↗
DOE OSTI2024

Single-Particle Soot Photometer (SP2) Black Carbon Number and Mass Concentrations

The single-particle soot photometer (SP2) records particle-by-particle measurements of the intensity of both the scattering signature and incandescence signature of particles that enter its laser beam. These intensities are then used to calculate refractory black carbon (rBC) masses and particle diameters. In previous U.S. Department of Energy Atmospheric Radiation Measurement (ARM) user facility field campaigns, the SP2 data was difficult to process because the manufacturer-supplied code was not scalable to distributed machines, making it unusable for the large amounts of data output by the SP2. This prohibited the SP2 from becoming an operational instrument for ARM. Therefore, PySP2 was developed to solve this issue and enable SP2 to be an operational instrument for ARM. This technical document summarizes the test data sets from the ARM North Slope of Alaska (NSA) site and the Multidisciplinary Drifting Observatory for the Study of Arctic Climate (MOSAiC) field campaign that were used to develop and test PySP2.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Laser Wakefield Accelerator modelling with Variational Neural Networks

A machine learning model was created to predict the electron spectrum generated by a GeV-class laser wakefield accelerator. The model was constructed from variational convolutional neural networks, which mapped the results of secondary laser and plasma diagnostics to the generated electron spectrum. An ensemble of trained networks was used to predict the electron spectrum and to provide an estimation of the uncertainty of that prediction. It is anticipated that this approach will be useful for inferring the electron spectrum prior to undergoing any process that can alter or destroy the beam. In addition, the model provides insight into the scaling of electron beam properties due to stochastic fluctuations in the laser energy and plasma electron density.

43 PARTICLE ACCELERATORS↗