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DOE OSTI2020

Correlation approach for quality assurance of additive manufactured parts based on optical metrology

Surface topography and surface finish are two significant factors for evaluating the quality of products in additive manufacturing (AM). AM parts are fabricated layer by layer, which is quite different from traditional formative or subtractive methods. Despite rapid progress in additive manufacturing and associated optical metrology for quality control and in-situ monitoring, limited research has been conducted to investigate the reliability of 3D surface measurement data. The surface topologies scanned by multiple optical systems demonstrated significant differences due to varying sampling mechanisms, resolutions, system noises, etc. The 3D datasets should be trustworthy in order to extract parameters for quality assurance or feedback control from 3D surface measurements. In this paper, we set up new standards to evaluate the reliability of 3D surface measurement data and analyze the variation in the topographical profile. In this study, two non-contact optical methods based on Focus Variation Microscopy (FVM) and Structured Light System (SLS) were adopted to measure the surface topography of the target components. The two optical metrology systems generated two entirely different point cloud datasets. Statistical methods were applied to test the difference between the data obtained from the two systems. By using a data analytics approach for comparison, it was found that the surface roughness estimated from the point cloud data sets of FVM and SLS has no significant difference, though the point cloud data sets were completely different. This paper provides standard validation approach to evaluate the plausibility of metrology data from in-situ real-time surface analysis for process planning of AM.

36 MATERIALS SCIENCE↗

NASA NTRS1976

The Surface Chemical Composition of Lunar Samples and Its Significance for Optical Properties

The surface iron, titanium, calcium, and silicon concentration in numerous lunar soil and rock samples was determined by Auger electron spectroscopy. All soil samples show a large increase in the iron to oxygen ratio compared with samples of pulverized rock or with results of the bulk chemical analysis. A solar wind simulation experiment using 2 keV energy alpha -particles showed that an ion dose corresponding to approximately 30,000 years of solar wind increased the iron concentration on the surface of the pulverized Apollo 14 rock sample 14310 to the concentration measured in the Apollo 14 soil sample 14163, and the albedo of the pulverized rock decreased from 0.36 to 0.07. The low albedo of the lunar soil is related to the iron + titanium concentration on its surface. A solar wind sputter reduction mechanism is discussed as a possible cause for both the surface chemical and optical properties of the soil.

Gold, T.↗

DOE OSTI2023

Visual, Optical and Replica Inspections: Surface Preparation of 650 MHz NB Cavity for PIP-II Linac

Surface preparation of niobium superconducting RF cavities is a critical step for achieving good RF performance under the superconducting state. Surface defect, roughness, and contamination affect the accelerating gradient and quality factor of the cavities. We report surface inspection methods used to control the surface processing of 650 MHz cavities designated for the pre-production and prototype cryomodules for PIP-II linac. The cavity surface was routinely inspected visually, with an optical camera, and by microscopic scanning of surface replicas. This article covers details on the surface inspection methods and surface polishing process used to repair the surface.

43 PARTICLE ACCELERATORS↗

NASA NTRS1976

The scattering of obliquely incident plane waves from a corrugated conducting surface

A physical optics solution is presented for the scattering of plane waves from a perfectly conducting corrugated surface in the case of waves incident from an arbitrary direction and for an observer far from the surface. This solution is used to compute the radar cross section of the surface in the case of backscatter from irregular (i.e., stochastic) corrugations. An interesting feature of the solution is the occurrence of singularities in the scattered fields. These singularities appear to be a manifestation of focusing by the surface at its 'stationary' points. Whether or not the singularities occur in the solution depends on the manner in which one restricts the analysis to the far-field.

Surface waves↗

NASA NTRS1995

Study of surfaces using near infrared optical fiber spectrometry

The measurement and control of cleanliness for critical surfaces during manufacturing and in service provides a unique challenge for fulfillment of environmentally benign operations. Of particular interest has been work performed in maintaining quality in the production of bondline surfaces in propulsion systems and the identification of possible contaminants. This work requires an in-depth study of the possible sources of contamination, methodologies to identify contaminants, discrimination between contaminants and chemical species caused by environment, and the effect of particular contaminants on the bondline integrity of the critical surfaces. This presentation will provide an introduction to the use of optical fiber spectrometry in a nondestructive measurement system for process monitoring and how it can be used to help clarify issues concerning surface chemistry. Correlation of the Near Infrared (NIR) spectroscopic results with Optical Stimulated Electron Emission (OSEE) and ellipsometry will also be presented.

Workman, G. L.↗

NASA NTRS1972

Optimum detection of an optical image on a photoelectric surface

The detection of an optical image in the presence of uniform background light is based on a likelihood ratio formed of the numbers of photoelectrons emitted from small elements of a photoelectric surface onto which the image is focused. When diffraction is negligible and the surface has unit quantum efficiency, this detector is equipollent with the optimum detector of the image forming light. Its performance is compared with that of the threshold detector and that of a detector basing its decisions on the total number of photoelectrons from a finite area of the image. The illuminance of the image is postulated to have a Gaussian spatial distribution. All three detectors exhibit nearly the same reliability.

Helstrom, C. W.↗

NASA NTRS1989

Space optical materials and space qualification of optics; Proceedings of the Meeting, Orlando, FL, Mar. 30, 31, 1989

The present conference on space optical materials discusses current metals and nonmetals-related processing R&D efforts, investigations of space optical effects, and the spaceborne qualification of optical components and systems. Attention is given to CVD SiC for optical applications, optical materials for space-based lasers, the high-efficiency acoustooptic and optoelectronic crystalline material Tl3AsSe3, HIPed Be for low-scatter cryogenic optics, durable solar-reflective surfacing for Be optics, thermal effects on Be mirrors, contamination effects on optical surfaces in the monolayer regime, and IR background signature survey experiment results. Also discussed are the contamination-control program for the EUE instrument, an optical multipass radiation system for the heating of levitated samples, optical sample-position sensing for electrostatic levitation, and the qualification of space lighting systems.

Hale, Robert R.↗

NASA NTRS2012

Techniques for Solution- Assisted Optical Contacting

A document discusses a solution-assisted contacting technique for optical contacting. An optic of surface flatness Lambda/20 was successfully contacted with one of moderate surface quality, or Lambda/4. Optics used were both ultra-low expansion (ULE) glass (Lambda/4 and Lambda/20) and fused silica (Lambda/20). A stainless steel template of the intended interferometer layout was designed and constructed with three contact points per optic. The contact points were all on a common side of the template. The entire contacting jig was tilted at about 30 . Thus, when the isopropanol was applied, each optic slid due to gravity, resting on the contact points. All of the contacting was performed in a relatively dusty laboratory. A number of successful contacts were achieved where up to two or three visible pieces of dust could be seen. These were clearly visible due to refraction patterns between the optic and bench. On a number of optics, the final step of dropping isopropyl between the surfaces was repeated until a successful contact was achieved. The new procedures realized in this work represent a simplification for optical contacting in the laboratory. They will both save time and money spent during the contacting process, and research and development phases. The techniques outlined are suitable for laboratory experiments, research, and initial development stages.

DeVine, Glenn↗

NASA NTRS2003

Response Surface Methods For Spatially-Resolved Optical Measurement Techniques

Response surface methods (or methodology), RSM, have been applied to improve data quality for two vastly different spatially-resolved optical measurement techniques. In the first application, modern design of experiments (MDOE) methods, including RSM, are employed to map the temperature field in a direct-connect supersonic combustion test facility at NASA Langley Research Center. The laser-based measurement technique known as coherent anti-Stokes Raman spectroscopy (CARS) is used to measure temperature at various locations in the combustor. RSM is then used to develop temperature maps of the flow. Even though the temperature fluctuations at a single point in the flowfield have a standard deviation on the order of 300 K, RSM provides analytic fits to the data having 95% confidence interval half width uncertainties in the fit as low as +/- 30 K. Methods of optimizing future CARS experiments are explored. The second application of RSM is to quantify the shape of a 5-meter diameter, ultra-lightweight, inflatable space antenna at NASA Langley Research Center. Photogrammetry is used to simultaneously measure the shape of the antenna at approximately 500 discrete spatial locations. RSM allows an analytic model to be developed that describes the shape of the majority of the antenna with an uncertainty of 0.4 mm, with 95% confidence. This model would allow a quantitative comparison between the actual shape of the antenna and the original design shape. Accurately determining this shape also allows confident interpolation between the measured points. Such a model could, for example, be used for ray tracing of radio-frequency waves up to 95 GHz. to predict the performance of the antenna.

Danehy, P. M.↗

NASA NTRS2003

Response Surface Methods for Spatially-Resolved Optical Measurement Techniques

Danehy, P. M.↗

NASA NTRS1997

Study of SRM Critical Surfaces Using Near Infrared Optical Fiber Spectrometry

The measurement and control of cleanliness for critical surfaces during manufacturing and in service operations provides a unique challenge in the current thrust for environmentally benign processes. Of particular interest has been work performed in maintaining quality in the production of bondline surfaces in propulsion systems and the identification of possible contaminants which are detrimental to the integrity of the bondline. This work requires an in-depth study of the possible sources of contamination, methodologies to identify contaminants, discrimination between contaminants and chemical species caused by environment, and the effect of particular contaminants on the bondline integrity of the critical surfaces. This paper will provide an introduction to the use of Near Infrared (NIR) optical fiber spectrometry in a nondestructive measurement system for process monitoring and how it can be used to help clarify issues concerning surface chemistry. In a previous conference, experimental results for quantitative measurement of silicone and Conoco HD2 greases, and tape residues on solid rocket motor surfaces were presented. This paper will present data for metal hydroxides and discuss the use of the integrating sphere to minimize the effects of physical properties of the surfaces (such as surface roughness) on the results obtained from the chemometric methods used for quantitative analysis.

Workman, G. L.↗

DOE OSTI2024

First Time-Resolved Leader Spectra Associated With a Downward Terrestrial Gamma-Ray Flash Detected at the Telescope Array Surface Detector

Optical emissions associated with Terrestrial Gamma ray Flashes (TGFs) have recently become important subjects in space-based and ground-based observations as they can help us understand how TGFs are produced during thunderstorms. In this paper, we present the first time-resolved leader spectra of the optical component associated with a downward TGF. The TGF was observed by the Telescope Array Surface Detector (TASD) simultaneously with other lightning detectors, including a Lightning Mapping Array (LMA), an INTerFerometer (INTF), a Fast Antenna (FA), and a spectroscopic system. The spectroscopic system recorded leader spectra at 29,900 frames per second (33.44 μs time resolution), covering a spectral range from 400 to 900 nm, with 2.1 nm per pixel. The recordings of the leader spectra began 11.7 ms before the -18 kA return stroke and at a height of 2.37 km above the ground. These spectra reveal that optical emissions of singly ionized nitrogen and oxygen occur between 167 μs before and 267 μs after the TGF detection, while optical emissions of neutrals (H I, 656 nm; N I, 744 nm, and O I, 777 nm) occur right at the moment of the detection. The time-dependent spectra reveal differences in the optical emissions of lightning leaders with and without downward TGFs.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1992

Gas-exposure enhanced Na* emission from Na-rich surfaces

The optical emission attributed to electronically desorbed excited sodium atoms from NaCl and Na-evaporated surfaces is shown to be enhanced by exposure of the surface to gaseous CO2 and N2. This is the first observation of enhancement of electron-simulated desorption of substrate atoms caused by the exposure of surfaces to gaseous molecules which do not contain the desorbed atoms. The large amount of excited-sodium yield at 60 K provides evidence for nonexistence of the secondary-electron excitation of thermally desorbed ground sodium.

Xu, Jun↗

NASA NTRS1987

A physical optics correction for backscattering from curved surfaces

The conventional physical optics (PO) approximation used to calculate the scattered fields from a conducting body leads to incorrect scattered fields even in the specular reflection region. This is true even when all other subdominant terms are assumed to be absent. The inaccuracy stems from the fact that the surface currents used in the PO approximation suddenly truncate at the shadow boundary of curved surfaces resulting in an erroneous contribution. Expressions for these shadow boundary (end point) contributions are presented in this paper. It is shown that if these end point contributions are substracted from the conventional PO results, one obtains a better representation of the true scattered field. For illustration, backscattered fields from various conducting bodies are computed using the corrected PO solution and are compared with the exact scattered fields.

Gupta, Inder J.↗

NASA NTRS1990

Surface-crack growth: Models, experiments, and structures; Proceedings of the Symposium, Sparks, NV, Apr. 25, 1988

The present volume on surface-crack growth modeling, experimental methods, and structures, discusses elastoplastic behavior, the fracture analysis of three-dimensional bodies with surface cracks, optical measurements of free-surface effects on natural surfaces and through cracks, an optical and finite-element investigation of a plastically deformed surface flaw under tension, fracture behavior prediction for rapidly loaded surface-cracked specimens, and surface cracks in thick laminated fiber composite plates. Also discussed are a novel study procedure for crack initiation and growth in thermal fatigue testing, the growth of surface cracks under fatigue and monotonically increasing load, the subcritical growth of a surface flaw, surface crack propagation in notched and unnotched rods, and theoretical and experimental analyses of surface cracks in weldments.

Reuter, Walter G.↗

NASA NTRS1984

Spacecraft contamination: Sources and prevention; Thermophysics Conference, 18th, Montreal, Canada, June 1-3, 1983, Selected Papers

Results of current research in the field of spacecraft contamination are presented. An overview of the various sources of contamination is given, showing the many and diverse mechanisms associated with the degradation of thermal and optical performance of spacecraft surfaces and optics. Some of the causes of contamination are discussed, including spallation of foam insulation on cryogenic fuel tanks, dispersion of particle contamination about a spacecraft, particle contamination of optical sensors, and the influence of the location of venting systems. Contamination prevention is addressed. Infrared transmittance and infrared optical properties of contaminants are considered along with the effects and properties of mixtures of exhaust species, of plume boundary layer flow, and of the contamination associated with bipropellant attitude control thrusters proposed for the Galileo spacecraft. Also discussed are: degradation of 'clean' thermal control surfaces over four years in orbit, in-orbit measurement of solar absorptance, and contamination from postfire efflux of a solid-propellant rocket motor.

Roux, J. A.↗

DOE OSTI2024

Laser micro-machining and damage testing of rounded shadow cone blockers on silica glass for arresting laser damage growth by redirection of light

Structured conical blockers manufactured on optical input surfaces are being used to shadow, and thereby, arrest growth of exit surface damage on large optics for applications in high-energy laser systems to extend their lifetime usage. However, as the size of the Shadow Cone Blocker (SCB) is increased, the deflected light must be carefully managed to prevent consequential damage from downstream intensification. Here, we design and fabricate a distinct input SCB geometry to alleviate this problem, enabling larger damage site mitigation. The demonstrated ~1 mm diameter SCB was manufactured with a convergent approach using a CO 2 pulsed laser ablative scanning sequence on a fused silica window. The SCB design was refined to maximize resistance to both input and exit surface damage initiations on 1 cm thick fused silica windows when exposed to 351 nm irradiation and validated with laser damage testing. The design showed to prevent damage onset to the exit surface for incident fluences on the SCB of 10.7 ± 1.3 J·cm -2 and is resistant to damage on the input surface exceeding 30 J·cm -2 input fluence.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Mirrors for petawatt lasers: Design principles, limitations, and solutions

High intensity and high energy laser facilities place increasing demands on optical components, requiring large surface area optics with exacting specifications. Petawatt lasers are high energy, short-pulse laser systems generally based on chirped-pulse amplification, where an initial low energy short pulse is stretched, amplified, and then recompressed to produce fs to ps high-power laser pulses. In such petawatt lasers, the highest demands are placed on the final optics, including gratings which compress the pulses and mirrors which direct and focus the final high-power beams. The limiting factor in these optical components is generally laser-induced damage. Designing and fabricating these optical components to meet reflection, dispersion, and other requirements while meeting laser-induced damage requirements is the primary challenge discussed in this tutorial. We will introduce the reader to the technical challenges and tradeoffs required to produce mirrors for petawatt lasers and discuss current research directions.

47 OTHER INSTRUMENTATION↗