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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

High-Enthalpy Testing to Validate Simulation of an Aerosol Capture Probe

AERACEPT (Aerosol Rapid Analysis Combined Entry Probe/sonde Technology) is a developing technology enabling in-situ aerosol particle sampling and analysis in a small spacecraft mission envelope. It integrates a passive aerosol sample collection system into a probe’s thermal protection system (TPS) to remove the need for heat shield separation and active descent control (parachutes, gliders, etc.). AERACEPT is being validated against the requirements of the Nephele mission concept, which targets the middle and lower Venus cloud layers. The proposed technology employs 3D Carbon-Carbon (3D-CC) at the probe’s nose to withstand the extreme environments encountered in a Venus entry without producing pyrolysis gases that would contaminate the mission sample collection. Any shape change of this 3D-CC sample inlet will affect airflow through the sampling system, thereby impacting aerosol sample collection bias and efficiency. Accurate prediction of the nose’s material response during entry is there-fore of fundamental importance to the development and practical use of this technology. As a result, the AERACEPT project is planning a test campaign in the newly built PlasmatronX facility with a novel “Open Iso-Q” test article to validate state-of-the-art material response tools for a simulated Venus entry. The PlasmatronX is a 350 kW inductively-coupled plasma facility developed and run by the Center for Hypersonics and Entry Systems Studies at the University of Illinois at Urbana-Champaign. The facility can support ground testing for a variety of planetary destinations by simulating entry conditions in Nitrogen, Air, and Carbon Dioxide. To best simulate the Venus atmosphere and match flight-like recession, the planned AERACEPT test campaign will use Carbon Dioxide as its test gas. AERACEPT has designed two test articles for this campaign: 1) a standard test article whose curved surface approximates a constant applied heat flux (“Closed Iso-Q” model) and 2) a novel inlet test article with a through-hole at the stagnation point (“Open Iso-Q” model). Both article types consist of a 3D-CC sample bonded to a graphite fixture. All articles will be laser scanned before and after testing to estimate shape change and recession, and the “Closed Iso-Q” articles will be instrumented with thermocouples to provide temperature histories. The test article temperatures and inlet shape change will be compared against simulations run with the Porous material Analysis Toolbox based on OpenFOAM (PATO) to validate the AERACEPT 3D-CC material response model. Due to the high thermal conductivity of 3D-CC, multidimensional effects have a large influence on the test article temperature and the standard 1-D material response tools are not sufficient for test planning. The test campaign features (e.g. article design, run duration, heat fluxes) are therefore informed by a series of 3-D simulations using state-of-the-art material response tools such as PATO. The test campaign is scheduled for spring of 2024. Expected results include 1) Key drivers of selected test conditions (e.g. matching mission flight atmosphere & recession), 2) Simulation results that informed test article design, 3) Acquired test data such as recession measurements, temperature histories, and photos, and 4) Comparisons between test results and simulation predictions.

AERACEPT↗
NASA NTRSDate not supplied

Laser Ablative Patterning of B4C and MoAlB Ceramics for Hydrophobic Surfaces

Through a novel laser ablative patterning (LAP) process, the present work reports the increase in wetting contact angle of molybdenum aluminum boride (MoAlB) and the reduction of dust adhesion. The LAP technique employed picosecond laser pulses to form a crosshatch pattern with micropillars on ceramic surfaces. The wetting behavior was successfully transitioned from hydrophilic (θ < 90°) to hydrophobic (θ > 90°), which may be related to Wenzel or Cassie-Baxter mechanisms. Parameters such as laser fluence and number of laser scans were varied to study their effects on ceramic surface characteristics. Dust adhesion experiments were performed on these hydrophobic ceramic surfaces, which showed that the adhesion of lunar soil simulant dust particles was significantly reduced in the patterned MoAlB surface. The patterned MoAlB samples were further examined using the surveying lunar dust influence on device efficacy (SLIDE) testbed to evaluate the wear performance.

Bai Cui↗
DOE OSTI2023

Three-dimensional broadband nonlinear phased array imaging

System include an ultrasonic transducer configured to couple to a nondestructive testing (NDT) sample and configured to produce and direct an ultrasonic probe wave at a selected frequency into a subsurface region of the NDT sample, a 3D laser scanning vibrometer configured to direct a detection beam in a scan area on a surface of the NDT sample and to receive a return beam from the scan area, and to detect, based on the return beam, a 3D motion of the surface across a wideband frequency range, and a processor, and a memory configured with instructions that, when executed by the processor, cause the processor to produce sub-surface image data of the NDT sample at multiple harmonics of the selected frequency in the wideband frequency range based on the detected 3D surface motion, wherein the sub-surface image data describes a nonlinear defect response produced in the NDT sample by interaction of the ultrasonic probe wave with the subsurface region.

Remillieux, Marcel↗
DOE OSTI2024

General Testing Setup for Hyperelastic Transducers-DEEC-Tec & Marine Renewable Energy: Preprint

Distributed embedded energy conversion technologies (DEEC-Tec), an emerging domain for ocean wave energy conversion technology, is showing promise for a range of applications. Research is being conducted at the National Renewable Energy Laboratory that leverages this domain to investigate the potential of ocean wave energy converters (WECs) constructed from hyperelastic forms of distributable and embeddable energy transducers. These transducers are available in forms such as disks, rectangles, or hexagons and can be combined in various ways to form energy-producing metamaterials and flexible WECs. DEEC-Tec, therefore, could open doors that enhance ocean wave energy conversion in ways not previously thought possible by allowing for many WEC topologies and morphologies. However, the same diversity and adaptability pose challenges for the development of these DEEC-Tec-oriented hyperelastic transducers. A commercial tensile testing setup was not found that was adaptable enough to accommodate the varied transducers while providing precise force control, range of motion, and noncontact data collection. Because of this lack, a comprehensive test rig was designed in house to be used with a 3D laser scanning device-providing contactless measurements while also allowing for different geometries and various uniaxial loadings. This paper and presentation will discuss these unique challenges and the processes for overcoming them to provide a robust and general testing setup for hyperelastic transducers, of any form, for the DEEC-Tec marine renewable energy domain.

DEEC-Tec↗
NASA NTRSDate not supplied

Towards Simultaneous Multi-Parameter Measurements Using Burst-Mode Frequency-Scanning Planar Laser-Induced Fluorescence

While planar laser-induced fluorescence (PLIF) can provide valuable flow visualization, there are many challenges in extracting quantitative measurements from the fluorescence intensity. To overcome the multi-parameter dependence of the signal intensity, frequency scanning planar laser-induced fluorescence (FS-PLIF) provides the potential for 2D temperature, pressure, and velocity measurements by spectrally resolving the excitation spectrum of one or more fluorescence transitions to extract the Doppler shift, Doppler- and collisional-broadening of absorption lines, and the relative signal intensities of multiple transitions. This work aims to characterize a burst-mode FS-PLIF system consisting of a Spectral Energies, LLC burst-mode laser coupled with a Spectral Energies, LLC optical parametric oscillator using nitric oxide (NO) static pressure cell measurements. The effect of the OPO cavity on intensity fluctuations during frequency-scanning is investigated. A NO PLIF model is implemented to investigate the feasibility of property measurements using single- and two-NO-line scans.

burst-mode laser↗
DOE OSTI2024

Thermal scanning probe and laser lithography for patterning nanowire based quantum devices

Semiconductor nanowire (NW) quantum devices offer a promising path for the pursuit and investigation of topologically-protected quantum states, and superconducting and spin-based qubits that can be controlled using electric fields. Theoretical investigations into the impact of disorder on the attainment of dependable topological states in semiconducting nanowires with large spin–orbit coupling and g-factor highlight the critical need for improvements in both growth processes and nanofabrication techniques. In this work, we used a hybrid lithography tool for both the high-resolution thermal scanning probe lithography and high-throughput direct laser writing of quantum devices based on thin InSb nanowires with contact spacing of 200 nm. Electrical characterization demonstrates quasi-ballistic transport. The methodology outlined in this study has the potential to reduce the impact of disorder caused by fabrication processes in quantum devices based on 1D semiconductors.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A Bezier Curve Informed Melt Pool Geometry to Model Additive Manufacturing Microstructures Using SPPARKS

Additive manufacturing is a transformative technology with the potential to manufacture designs which traditional subtractive machining methods cannot. Additive manufacturing offers fast builds at near final desired geometry; however, material properties and variability from part to part remain a challenge for certification and qualification of metallic components. AM induced metallic microstructures are spatially heterogeneous and highly process dependent. Engineering properties such as strength and toughness are significantly affected by microstructure morphologies resulting from the manufacturing process Linking process parameters to microstructures and ultimately to the dynamic response of AM materials is critical to certifying and qualifying AM built parts and components and improving the performance of AM materials. The AM fabrication process is characterized by building parts layer by layer using a selective laser melt process guided by a computer. A laser selectively scans and melts metal according to a designated geometry. As the laser scans, metal melts, fuses, and solidifies forming the final geometry in a layerwise fashion. As the laser heat source moves away, the metal cools and solidifies forming metallic microstructures. This work describes a microstructure modeling application implemented in the SPPARKS kinetic Monte Carlo computational framework for simulating the resulting microstructures. The application uses Bzier curves and surfaces to model the melt pool surface and spatial temperature profile induced by moving the laser heat source; it simulates the melting and fusing of metal at the laser hot spot and microstructure formation and evolution when the laser moves away. The geometry of the melt pool is quite flexible and we explore effects of variances in model parameters on simulated microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗
NASA NTRS1977

Optical scanning system for laser velocimeter

Tests, using towed models of large aircraft with small trailing models through still-air test zone, have been designed to analyze wake vortex phenomena. Analyzing velocity profiles as function of time, information is developed on generation and decay of wake vortex. System is improvement over laser velocimeter (LV) products and is anticipated to have many applications in research and commercial products.

Rhodes, D. B.↗
DOE OSTI2024

Recycling of silver from silicon solar cells by laser debonding

A laser-debonding approach to silver electrode recovery from solar cells is presented to address the critical need for efficient and eco-friendly recycling methods. The study explores the use of UV nanosecond and IR continuous-wave lasers to precisely debond silver electrodes from silicon wafers. By optimizing parameters like laser power, scan speed, and the number of passes, intact silver electrical contact lines were recovered from solar cells. Scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS) analysis confirmed the successful separation of silver from silicon wafers. Furthermore, an increase in the number of laser passes led to the production of silver microparticles, as validated by morphology and compositional studies using EDS. The estimated silver is approximately 90 mg for the Si solar cells of 15.4 * 15.4 cm 2 used in the study. To achieve a large area recovery of silver, a MATLAB code incorporating detection algorithms and specific criteria to automate laser scanning by accurately identifying the location of silver electrodes was developed. This presented laser debonding method is not confined to silicon solar cells but can be extended to other solar cell types featuring metal electrodes, offering a versatile solution. By minimizing the use of hazardous chemicals and reducing operational costs, the developed process aligns with the imperative of environmentally responsible photovoltaic waste management.

14 SOLAR ENERGY↗
NASA NTRS1978

Laserfax

The photo shows an Associated Press technician receiving a photograph prepared by means of a high speed, high resolution facsimile system known as Laserfax, so called because it employs a laser beam to scan the photo being sent. Laser scanning data is converted to electrical signals and transmitted to news bureaus within the Associated Press network via microwave radio or telephone lines. At the other end, another laser sweeps reconverted imagery onto a special, light-sensitive, dry silver paper. The paper is then heat processed to reproduce the photograph. Manufactured by Harris Electronics Systems Inc., Melbourne, Florida, Laserfax incorporates NASA thermal control coating technology developed by Jet Propulsion Laboratory for use on spacecraft antennas; the coatings block absorption of solar radiation which would interfere with the antenna's proper operation. Harris Electronics Systems, originally Radiation, Inc., reused the NASA technology in development of Laserfax. A NASA technical support package provided information about the thermal properties that could be expected of various coatings for the facsimile system's paper rollers; this information served as a design base for the infrared heat source used in developing the photo. Although relatively new, Laserfax is in extensive service. It is manufactured in several models. One of them is the type used by the Associated Press, its news bureaus and affiliated newspapers, radio and television stations. Other models have been sold in large numbers to law enforcement agencies for transmitting high quality fingerprints and identification photos. Laserfax is also in service with the National Weather Service, which converts satellite imagery to weather photographs and relays them to local weather stations, television stations, newspapers and airlines.

Source record↗
DOE OSTI2026

Optimization of Processing, Microstructure, and Hardness of an Al–Ce–Ni–Mn–Zr Alloy With Laser Additive Manufacturing

Here, this study examines the processing behavior, microstructure, surface roughness, and hardness properties of an aluminum alloy containing 8.2 Ce, 4.5 Ni, 0.5 Mn, and 0.7 Zr (wt%) fabricated using laser powder bed fusion. Sixty samples were produced across a range of laser powers, scan speeds, and hatch spacings to evaluate their effect on porosity, hardness, and microstructural features. Porosity was measured using X-ray computed tomography, while microstructure and surface roughness were characterized by scanning electron (SEM) and laser confocal microscopy. High dense and cracking-free Al–Ni–Ce alloy was successfully manufactured. Porosity showed a U-shaped dependence on energy input, increasing under both insufficient and excessive melting conditions. Hardness increased with cooling rate due to finer cellular structures and solute redistribution. A general statistical model was developed to capture the relationships between processing parameters and material response. Results identify a narrow processing window defined by laser powers between 350 and 370 W, scan speeds from 1400 to 1800 mm/s, and hatch distances between 0.14 and 0.18 mm. Within this window, porosity is minimized (below 0.01%) and hardness is maximized (up to 160 HV), demonstrating that careful control of these parameters enables dense, high strength aluminum components suitable for demanding structural applications.

Aluminum alloys↗
NASA NTRS1998

development of a medium repetition rate (10 Hz - 500 Hz) diode pumped laser transmitter for airborne scanning altimetry

Since the late 1980's, NASA has developed several small, all-solid state lasers of low repetition rates for use as transmitters in prototype LIDAR and raster scanned altimetry retrieval systems. Our early laser transmitters were developed for high resolution airborne altimetry which employed cavity dumping techniques to produce a pulse shape with a 1 ns rise time. The first such laser was the SUMR (Sub-millimeter resolution) transmitter which used a side pumped, D-shaped half-rod of Nd:YAG for the oscillator active media and produced approximately 3 ns pulses of 100 micro-J energy at a 40 Hz repetition rate. (Coyle and Blair, 1993; Coyle et al., 1995) After several upgrades to improve rep rate and pulse energy, the final version produced 1.2 mJ pulses at 120 Hz with a 3.7 ns pulse width. The laser has become known as SPLT (Sharp Pulsed Laser Transmitter), and has flown successfully on a variety of airborne altimetry missions. (Coyle and Blair, 1995; Blair et al., 1994) From building these systems, we have accrued valuable experience in delivering field-deployable lasers and have become aware of the advantages and disadvantages of employing new technologies. For example, even though the laser's main operating environment is in a "cold" aircraft during flight, the laser must still operate in very warm temperatures. This is important if the mission is based in the desert or a tropical climate since ground calibration data from stationary targets must be gathered before and after each data flight. Because conductive cooling is much more convenient than closed loop water flow, achieving the highest possible laser efficiency is becoming a high priority when designing a flight laser. This is especially true for lasers with higher pulse energies and repetition rates which are needed for high altitude scanning altimeters and LIDARs.

Coyle, D. Barry↗
NASA NTRS1977

Demonstration of rapid-scan two-dimensional laser velocimetry in the Langley Vortex Research Facility for research in aerial applications

Tests were conducted to demonstrate a rapid scan two dimensional laser velocimeter (LV) measurement technique for aerial applications research. The LV system is capable of simultaneously measuring both vertical and axial flow velocity components in a near or far field vortex system. Velocity profiles were successfully measured in the wake vortex of a representative agricultural aircraft model, with the vortex system rapidly transporting in ground effect. Results indicate that the laser velocimetry technique can provide quantitative information of wake vortex characteristics in ground effect.

Gartrell, L. R.↗
DOE OSTI2026

Which way does the dendrite grow? Competition among epitaxy, preferred growth direction, and thermal gradients in powder bed fusion additive manufacturing

The as-processed microstructure of metal alloy parts manufactured through laser powder bed fusion (LPBF) is heavily derived from the cellular dendritic solidification. The growth direction of dendrites within the melt pool is determined through competition among epitaxial growth, preferred growth directions, and maximum thermal gradients. However, the dominant factor and the specific role of each in developing melt pool microstructures remain unknown. Here, in this study, we performed single laser track scans on an SS316L single crystal substrate and combined experimental characterization of microstructure and crystal orientations with Computational Fluid Dynamics simulations of thermal gradients to evaluate the role of each factor in determining dendritic growth direction and evolution. Our results reveal that epitaxial growth dominates microstructure development by preferentially growing along a single 〈100〉 variant of the single crystal substrate adjacent to the melt pool boundary. Under LPBF’s highly curved and rapidly evolving thermal field, this preferential dendrite variant selection and its continued growth from the melt pool boundary to the centerline are governed by the local temperature gradient magnitude at the solid-liquid interface, rather than by the instantaneous maximum temperature gradient direction alone. Using these findings, we successfully predict changes in the dendrite growth direction with changing laser scan direction on a single crystal substrate, and show that the geometric melt pool centerline can deviate from the microstructural centerline because asymmetric local temperature gradient magnitudes transiently limit growth, resulting in different dendrite travel distances on each side of the melt pool.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Laser Vacuum Furnace for Zone Refining

Laser beam scanned to produce moving melt zone. Experimental laser vacuum furnace scans crystalline wafer with high-power CO2-laser beam to generate precise melt zone with precise control of temperature gradients around zone. Intended for zone refining of silicon or other semiconductors in low gravity, apparatus used in normal gravity.

Griner, D. B.↗