Laser welding of coated magnet wire Final report
Laser techniques for welding polythermalese coated magnet wire to stainless steel and gold plated nickel terminals
WIRE↗
SEARCH · Search NASA
Results for “laser wire”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques
The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.
Additive Manufacturing↗
Manufacturing Process Applications Team (MATeam)
The activities of the Manufacturing Process Applications Team concerning the promotion of joint Industry/Federal Agency/NASA funded research and technology operating plan (RTOP) programs are reported. Direct transfers occurred in cutting tools, laser wire stripping, soldering, and portable X-ray unit technology. TROP program funding approval was obtained for the further development of the cutting tool Sialon and development of an automated nondestructive fracture toughness testing system.
Source record↗
Strainmeters and tiltmeters
The techniques and instrument designs developed for continuously recording tiltmeters and strainmeters are reviewed. Consideration is given to short-base and long-base tiltmeters as well as to rod, wire, laser and borehole hydraulic strainmeters. Since a good design is difficult to achieve, it is necessary to select the goals an instrument must meet and be prepared to compromise on others. The importance of comparison tests is demonstrated, and it is concluded that good results cannot be gotten at low cost or without careful attention to details.
Agnew, D. C.↗
Additive Manufacturing of Liquid Rocket Engine Combustion Devices: A Summary of Process Developments and Hot-Fire Testing Results
Additive Manufacturing (AM) of metals is a processing technology that has significantly matured over the last decade. For liquid propellant rocket engines, the advantages of AM for replacing conventional manufacturing of complicated and expensive metallic components and assemblies are very attractive. AM can significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing for use in liquid rocket engine component design, development, and testing since 2010. The AM technique most often used at the NASA MSFC has been powder-bed fusion or selective laser melting (SLM), although other techniques including laser directed energy deposition (DED), arc-based deposition, and laser-wire cladding techniques have also been used to develop several components. The purpose of this paper is to discuss the various internal programs at the NASA MSFC using AM to develop combustion devices hardware. To date at the NASA MSFC, combustion devices component hardware ranging in size from 100 lbf to 35,000 lbf have been designed and manufactured using SLM and deposition-based AM processes, and many of these pieces have been hot-fire tested. Combustion devices component hardware have included thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. Ongoing and future developments for combustion devices have also included design of components sized for boost-class engines. Several design and hot-fire test iterations have been completed on these subscale and larger scale components, and a summary of these results will be presented as well.
Gradl, Paul↗
Laser measuring system for wire-wrapped frame assemblies
The laser measuring system is designed to automatically measure and record the distances between small diameter wires on a wire wrapped grid frame assembly to an accuracy of 0.00635 mm (0.00025 in.). The system utilizes a helium-neon gas laser beam as the measuring instrument with a remote interferometer and retroreflector, a light source and photodetector to detect the wire positions, in conjunction with recording, display and printout units. The laser measuring system is utilized to perform precise automatic measurements for wire application machines or as an automatic feedback device for positioning wires and/or to adjust them for out of tolerance conditions.
Etzel, J. G.↗
Comparison of hot wire/laser velocimeter turbulence intensity measurements
The question of whether a random measure of particle velocities yields a good statistical estimate of the stationary condition of the turbulence flow field was investigated by comparing hot-wire and laser velocimeter turbulence intensity measurements. Great care was taken to insure that the instrument precision of both the laser velocimeter and hot wire was maximized. In this attempt to reduce the measurement uncertainties in the hot wire, direct digitization of the analog output signal was performed with point-by-point conversion to velocity through a spline fit calibration curve and the turbulence intensity function was calculated statistically. Frequent calibrations of the hot wire were performed using the laser velocimeter as the velocity standard to account for the presence of the small seed particles in the air flow and signal drift in the hot wire.
Meyers, J. F.↗
Interaction of high-powered focused laser beam with exploding wire.
Exploding wire heating technique using combination of focused laser beam electric field intensity and pulsed power electric current
Davis, P. W.↗
A comparison of turbulence intensity measurements using a laser velocimeter and a hot wire in a low speed jet flow
The study involves a simultaneous measurement with both instruments along radial scans at two axial locations in the jet exiting from the turbulent pipe and an axial scan at the 75-percent radial location in the jet from the convergent nozzle. The results suggest that, within the limits of flow stationarity, both instruments yield measurements in good agreement, + or - 0.8-percent in turbulence intensity, below a turbulence intensity (the ensemble standard deviation divided by the local mean velocity) of 20 percent. From turbulence intensities of 20 percent to a maximum of 75 percent, the measurements exhibit the same trends; for reasons discussed here, however, the comparisons are not of the quality as those below 20 percent. It is found that correcting the turbulence intensity data for velocity bias errors increases the results by an average of 2 percent in turbulence intensity above the hot wire results and the uncorrected laser velocimeter data. The results are seen as calling into question the validity of using the velocity bias correction and time average techniques for turbulence intensity measurements.
Meyers, J. F.↗
Turbulence and shear stress measurements in hypersonic flow
An assessment has been made of the potential for hot wire and laser anemometer measurements of turbulent fluctuations in hypersonic flow fields. The results of laser velocimeter experiments conducted in two hypersonic wind tunnels are reported and comparisons made with previous hot wire turbulence measurements. A new concept for the measurement of the compressible shear stress terms which combines the attributes of both hot wire and laser anemometry is presented.
Owen, F. K.↗
Excimer laser produced plasmas in copper wire targets and water droplets
Elastically scattered incident radiation (ESIR) from a copper wire target illuminated by a KrF laser pulse at lambda = 248 nm shows a dinstinct two-peak structure which is dependent on the incident energy. The time required to reach the critical electron density (n(sub c) approximately = 1.8 x 10(exp 22) electrons/cu cm) is estimated at 11 ns based on experimental results. Detailed ESIR characteristics for water have been reported previously by the authors. Initiation of the broadband emission for copper plasma begins at 6.5 +/- 1.45 ns after the arrival of the laser pulse. However, the broadband emission occurs at 11 +/- 0.36 ns for water. For a diatomic substance such as water, the electron energy rapidly dissipates due to dissociation of water molecules, which is absent in a monatomic species such as copper. When the energy falls below the excitation energy of the lowest electron state for water, it becomes a subexcitation electron. Lifetimes of the subexcited electrons to the vibrational states are estimated to be of the order of 10(exp -9) s. In addition, the ionization potential of copper (440-530 nm) is approximately 6 eV, which is about two times smaller than the 13 eV ionization potential reported for water. The higher ionization potential contributes to the longer observed delay time for plasma formation in water. After initiation, a longer time is required for copper plasma to reach its peak value. This time delay in reaching the maximum intensity is attributed to the energy loss during the interband transition in copper.
Song, Kyo-Dong↗
Propagation velocities of laser-produced plasmas from copper wire targets and water droplets
Experiments were performed to determine the plasma propagation velocities resulting from KrF laser irradiation of copper wire target (75 microns diameter) and water droplets (75 microns diameter) at irradiance levels ranging from 25 to 150 GW/sq cm. Plasma propagation velocities were measured using a streak camera system oriented orthogonally to the high-energy laser propagation axis. Plasma velocities were studied as a function of position in the focused beam. Results show that both the shape of the plasma formation and material removal from the copper wire are different and depend on whether the targets are focused or slightly defocused (approximately = 0.5 mm movement in the beam axis). Plasma formation and its position relative to the target is an important factor in determining the practical focal point during high-energy laser interaction with materials. At irradiance of 100 GW/sq cm, the air plasma has two weak-velocity components which propagate toward and away from the incident laser while a strong-velocity component propagates away from the laser beam as a detonation wave. Comparison of the measured breakdown velocities (in the range of 2.22-2.27 x 10(exp 5) m/s) for air and the value calculated by the nonlinear breakdown wave theory at irradiance of 100 GW/sq cm showed a quantitative agreement within approximately 50% while the linear theory and Gaussian pulse theory failed. The detonation wave velocities of plasma generated from water droplets and copper wire targets for different focused cases were measured and analyzed theoretically. The propagation velocities of laser-induced plasma liquid droplets obtained by previous research are compared with current work.
Song, Kyo-Dong↗
Simultaneous comparison of turbulent gas fluctuations by laser Doppler and hot wire.
Explore the source record for details and available documents.
Cliff, W. C.↗
AM Processes Part 2: Principles of Directed Energy Deposition
Directed Energy Deposition (DED) is one of the metal additive manufacturing processes which finds wider industrial applications, particularly for repair and reclamation, and for large structures. This course helps the attendees to understand the fundamental concepts of DED process and covers the topics such as, how the technology works, different DED processes, materials used, and typical applications where this technology is used. The discussion will have a focus on ASTM F3187 – Standard guide for Directed Energy Deposition of Metals. After completing this webinar the attendees will achieve the following: · Identify and understand the different types of DED processes · Understand how to select a DED process and trade criteria · Understand the various materials used for DED processes · Understand the core parameters for the DED processes · Determine potential parts and end application of DED technology
Additive Manufacturing↗
Turbulence measurements in a transonic boundary layer and free-shear flow using laser velocimetry and hot-wire anemometry techniques
Quantitative measurements of the turbulence fluctuations in velocity and mass flux have been obtained in Mach 0.6 and 0.8 turbulent boundary layer and free-shear layer flows by laser velocimetry and hot-wire anemometry techniques. To evaluate the effects of compressibility, these transonic data are compared to available incompressible and supersonic results. Based on some simplifying assumptions, estimates of the rms density fluctuations are made for which error bounds are given. In addition to these fluctuation data, the compressible mean velocity data obtained with the laser velocimeter are presented and compared to pitot tube results. The investigation was conducted in the Ames 6- by 6-Foot Supersonic Wind Tunnel at free-stream Mach numbers of 0.6 and 0.8 for a unit Reynolds number of about 10,000,000 per meter.
Johnson, D. A.↗
Apparatus and method for pulsed laser deposition of materials on wires and pipes
Methods and apparatuses are disclosed which allow uniform coatings to be applied by pulsed laser deposition (PLD) on inner and outer surfaces of cylindrical objects, such as rods, pipes, tubes, and wires. The use of PLD makes this technique particularly suitable for complex multicomponent materials, such as superconducting ceramics. Rigid objects of any length, i.e., pipes up to a few meters, and with diameters from less than 1 centimeter to over 10 centimeters can be coated using this technique. Further, deposition is effected simultaneously onto an annular region of the pipe wall. This particular arrangement simplifies the apparatus, reduces film uniformity control difficulties, and can result in faster operation cycles. In addition, flexible wires of any length can be continuously coated using the disclosed invention.
Fernandez, Felix E.↗
System Model for MEMS based Laser Ultrasonic Receiver
A need has been identified for more advanced nondestructive Evaluation technologies for assuring the integrity of airframe structures, wiring, etc. Laser ultrasonic inspection instruments have been shown to detect flaws in structures. However, these instruments are generally too bulky to be used in the confined spaces that are typical of aerospace vehicles. Microsystems technology is one key to reducing the size of current instruments and enabling increased inspection coverage in areas that were previously inaccessible due to instrument size and weight. This paper investigates the system modeling of a Micro OptoElectroMechanical System (MOEMS) based laser ultrasonic receiver. The system model is constructed in software using MATLAB s dynamical simulator, Simulink. The optical components are modeled using geometrical matrix methods and include some image processing. The system model includes a test bench which simulates input stimuli and models the behavior of the material under test.
Wilson, William C.↗
Hot-wire accuracy in supersonic turbulence from comparisons with laser-induced fluorescence
A hot-wire anemometer and a new, nonintrusive, laser-induced fluorescence (LIF) technique are used to survey a turbulent boundary layer in a supersonic channel flow at Mach no. 2.06. The purpose is to test the accuracy of using the hot wire to measure the fluctuation amplitudes of static temperature and density in a compressible turbulent flow by comparing the results with independent and direct LIF measurements. Several methods of hot-wire calibration and analysis are applied. With each method, the hot-wire response can be related primarily to fluctuations of mass flux and total temperature, from which fluctuations of static temperature and density are calculated. However, these calculations are shown to be valid only if the fluctuations in static pressure are negligible. The acquisition and the analysis of the hot-wire data are often simplified further by neglecting the effects of fluctuations in total temperature. Comparisons of the fluctuation amplitudes of temperature and density obtained by hot-wire and LIF measurements demonstrate that such assumptions might not always be warranted, even in apparently simple flows.
Logan, Pamela↗