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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Mechanisms of graphite ablation by sub-millisecond ytterbium fiber laser pulses

Graphite is a key material in a variety of cross-cutting applications in energy conversion, energy storage, and nuclear energy. Recently, temporally modulated continuous wave lasers have been shown to produce well-defined ablation features in graphite at relatively high processing speeds. In this work, we analyze in detail the laser ablation dynamics of single-pulse ablation in the sub-millisecond time regime to elucidate the origins of the resulting well-defined ablation craters using a combination of time-resolved emission imaging, diffuse reflection/scattering imaging, and optical emission spectroscopy. These multimodal in situ diagnostics revealed three main contributors to achieve well-defined ablation features: (1) rapid ejection of particles with ~100 m/s speed, (2) ablation of the graphite in the gaseous form, and (3) absence of bulk liquid motion, which is typically observed in laser processing of metals. Plasma plume formation was sustained throughout the duration of the laser pulse (500 μs). Here, this work provides insights into the complex physical and chemical mechanisms of sub-millisecond laser–matter interactions, which are critical for parameter space optimization and tailoring of laser machining and drilling processes.

42 ENGINEERING↗
NASA NTRS1992

Fabrication and testing of carbon-carbon grids for ion optics

Ion optics measuring 16.5 cm in diameter and 1.0 mm in thickness were fabricated from carbon-carbon composites that were woven from a high-tensile-modulus carbon fiber. Plate flatness varied by less than 0.05 mm. Several methods were investigated for forming ion-extraction apertures in the carbon-carbon plates, including laser machining, mechanical drilling, and conventional electric discharge machining. Tests conducted using a quartz dilatometer indicated that the coefficient of thermal expansion of the carbon-carbon plates varied between -0.51 to -1.8 x 10 exp -6/degree C at plate temperatures between 173-773 K. Sputter-erosion experiments indicate that carbon-carbon erodes at a rate approximately 25 percent below molybdenum under the same conditions. These material properties indicate that carbon-carbon may be superior to molybdenum for use as ion optics electrodes for ion engines.

Garner, Charles E.↗
DOE OSTI2025

Accurate and efficient predictions of keyhole dynamics in laser materials processing using machine learning-aided simulations

The keyhole phenomenon has been widely observed in laser materials processing, including laser welding, remelting, cladding, drilling, and additive manufacturing. Keyhole-induced defects, primarily pores, dramatically affect the performance of final products, impeding the broad use of these laser-based technologies. The formation of these pores is typically associated with the dynamic behavior of the keyhole. So far, the accurate characterization and prediction of keyhole features, particularly keyhole depth, as a function of time, has been a challenging task. In situ characterization of keyhole dynamic behavior using the synchrotron X-ray technique is informative but complicated and expensive. Current simulations are generally hindered by their poor accuracy and generalization abilities in predicting keyhole depths due to the lack of accurate laser absorptance data. In this study, we develop a machine learning-aided simulation method that accurately predicts keyhole dynamics, especially in keyhole depth fluctuations, over a wide range of processing parameters. In two case studies involving titanium and aluminum alloys, we achieve keyhole depth prediction with a mean absolute percentage error of 10 %, surpassing those simulated using the ray-tracing method with an error margin of 30 %, while also reducing computational time. This exceptional fidelity and efficiency empower our model to serve as a cost-effective alternative to synchrotron experiments. Our machine learning-aided simulation method is affordable and readily deployable for a large variety of materials, opening new doors to eliminate or reduce defects for a wide range of laser materials processing techniques.

Computational fluid dynamics↗
NASA NTRSDate not supplied

Laser Forming of Sheet Metal for In-Space Manufacturing Applications

As the in-space economy matures, the migration of typically Earth-bound manufacturing methods, such as metal forming and joining, up to space will be required to meet the increasing demand for refueling and supply depots, habitats, laboratories, lunar surface structures, and sites for deep-space exploration shipbuilding. Only in this way can the magnitude of individual structures begin to exceed what can be launched, deployed, docked, or inflated and allow true economies of scale to be unlocked in space. However, typical terrestrial methods of forming and shaping sheet metal require massive machinery with the ability to deflect reaction forces to a large mass in a fixed reference frame (Earth). To both limit up-mass required for manufacture and to mitigate the issues of reaction forces in the relative reference frames of space, a non-contact, laser-based method of forming metal sheet is proposed. NASA Marshall Space Flight Center (MSFC), in cooperation with DARPA and the University of Florida (UF), have begun investigation of non-contact methods of laser forming sheet metal in thermal vacuum (TVAC) conditions to great success. To date, several grades of aluminum, stainless steel, and titanium coupons have been formed via laser-induced internal stresses in these metals at both ambient atmosphere and vacuum conditions. Temperatures in these tests ranged from -120 to 60 C, and though the total energy required to induce strain does vary with workpiece temperature and environmental pressure, the method remains predictable and controllable for the materials investigated. It is believed that this method will revolutionize manufacturing in-space as it not only continues to build upon the capabilities of the laser (sensing, marking, cutting, drilling, joining, and now forming) as an all-in-one tool, but also reduces the need to counteract forming forces as would be required in mechanical bending. In theory, all required stress to induce bending is generated through thermal gradient and strain within the workpiece, meaning that the need for reaction control and fuel expense on-orbit will be limited. Archimedes once stated, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world”. With a laser as our lever and our workpiece its own fulcrum, we can move the world’s manufacturing into space.

Laser↗
NASA NTRS2021

AIAA Ascend 2021 Conference On Demand Manufacturing of Electronics Panel Abstract

1. Session Proposal o Session Title NASA’s In Space Manufacturing and the On Demand Manufacturing of Electronics o Session Topic Primary -- Space Logistics, Autonomy, and Robotics; Secondary – Transformative Research and Technologies o Session Format: Panel Discussion. o Requested Session Duration: 60 minutes o Short Session Description: The goal of NASA’s On Demand Manufacturing of Electronics project is to develop and demonstrate the feasibility of a low-gravity, on-demand manufacturing system for flexible hybrid electronic devices on the International Space Station. This panel will feature several key collaborators and team members from the commercial sector, academia, and internal to NASA, each of which are contributing an unique and vital role to the design and implementation of this new technology system. o Extended Session Description (Please describe in detail the activity proposed, including how you intend to use the requested session duration. This session description will be provided to the reviewers for consideration and will not be displayed in the online agenda.): The session will be moderated by Curtis Hill, the Project Lead for the On Demand Manufacturing of Electronics (ODME), and he will start by giving a brief introduction to the ODME project which is working to produce a demo system for the manufacturing of electronic devices on the International Space Station. Panelists consisting of collaborators and team members to the ODME project will then give a brief (~5 min) introduction highlighting their contributions to the project, followed by time for Q&A from the audience. The panel will consist of: 1. Kenneth Church, nScrypt. nScrypt is a leader in multi-material printing with a modular system that incorporates a direct write thick film print head, a polymer fused filament fabrication print head, a laser sintering attachment, a drill head attachment for milling, and a pick and place. The system can print a layer and scan for accuracy of prints. The combination of multiple print heads and scanning allows for the on-demand production of intricate electronic components. 2. Andy Kurk, TechShot, Inc. Techshot, Inc. has collaborated extensively with NASA on the in space manufacturing of both printed electronics and fused metal materials. They are currently working to develop and integrate a test system for printed electronics, and a flight demonstration on the International Space Station is anticipated in 2024. 3. Ed Hendricks, NextFlex. NextFlex has the goal of advancing the manufacture of flexible hybrid electronics in the U.S. They are working with ODME on the development of AstroSense, an additively manufactured, wireless, flexible, and wearable health sensor. 4. Dr. Pradeep Lall, Auburn University. Professor Lall is the MacFarlane Endowed Distinguished Professor in the Department of Mechanical Engineering with a Courtesy Joint Appointment in the Department of Electrical and Computer Engineering and a Courtesy Joint Appointment in the Department of Finance. He is collaborating with NASA’s ODME project to develop multilayer printable devices and to develop techniques to test the quality of a printed electronic device. 5. Dr. Wei Gao, California Institute of Technology. Professor Gao is an Assistant Professor of Medical Engineering. His group is developing fully printed, flexible, and wearable biosensors for crew health monitoring in collaboration with NASA’s ODME project. In addition, they are working on using sweat to power biofuel cells for wearable, self-powered electronic devices. 6. Beth Paquette, NASA Goddard. The ODME branch at NASA Goddard is spearheading a sounding rocket flight demo to prove the capability of a printed electronic device with multiple sensors. In addition, they focus on thin film and flexible energy storage evaluations. o Session Goal(s)/Outcome(s): Please list the learning objectives and/or tangible outcomes (technical paper or other publication). The goal of this session is to highlight the internal and collaborative efforts of NASA’s On Demand Manufacturing of Electronics project to develop a system for printing electronics that will be tested on the International Space Station in 2024. In addition, the session with facilitate discussion with the community on the state of the art of printable electronics, current challenges, and new avenues for collaboration.

Jennifer McInnis Jones↗
NASA NTRS2025

Laser Cutting of Anorthosite and Norite in Vacuum

Lasers have previously been evaluated to cut and drill through rock in high pressure and atmospheric conditions to support deep drilling for oil & gas, as well as breaking or cutting rock near the surface. This research evaluates using lasers to cut rocks in a lunar environment. Anorthosite and norite samples were cut in a rough vacuum (<1 Torr) environment using a continuous wave (CW) 2 kW laser. Power and cutting speed are varied to control the total power input. In total 30, 38mm cuts are performed with power levels ranging from 25% (525 W) to 100% (2100 W) and total energy inputs from 0.090 – 4.34 kJ/cm. The cuts are bisected and inspected with optical and scanning electron microscopy. The bisected areas are measured to determine the specific energy for material removal (J/mm 3 ) and the extent of the heat affected zone.

Laser Cutting↗
NASA NTRS1993

Preliminary Ar-40/Ar-39 age spectrum and laser probe dating of the M1 core of the Manson Impact Structure, Iowa: A K-T boundary crater candidate

Preliminary Ar-40/Ar-39 age spectrum and laser probe dating results from new drill core from the 35-km-diameter Manson Impact Structure (MIS), Iowa indicates a reasonable possibility that the MIS is a Cretaceous-Tertiary (K-T) boundary impact event. Several different types of samples from a melt-matrix breccia, a unit of apparent crater fill intersected by the M1 core, were analyzed. Ar-40/Ar-39 results from these samples indicate a maximum age for the MIS of about 65.4 plus or minus 0.4(2 sigma) Ma. Petrographic analyses of the samples indicate a high probability that all the dated samples from the melt-matrix breccia contain relict grains that were not entirely melted or degassed at the time of impact, suggesting that the actual age of the MIS could be somewhat younger than our preliminary results indicate. The results are consistent with a previously published age estimate of shocked microcline from the MIS central uplift of 65.7 plus or minus 1.0 Ma.

Kunk, M. J.↗
NASA NTRS2016

Final Report: Laser-Based Optical Trap for Remote Sampling of Interplanetary and Atmospheric Particulate Matter

Applicability to Early Stage Innovation NIAC Cutting edge and innovative technologies are needed to achieve the demanding requirements for NASA origin missions that require sample collection as laid out in the NRC Decadal Survey. This proposal focused on fully understanding the state of remote laser optical trapping techniques for capturing particles and returning them to a target site. In future missions, a laser-based optical trapping system could be deployed on a lander that would then target particles in the lower atmosphere and deliver them to the main instrument for analysis, providing remote access to otherwise inaccessible samples. Alternatively, for a planetary mission the laser could combine ablation and trapping capabilities on targets typically too far away or too hard for traditional drilling sampling systems. For an interstellar mission, a remote laser system could gather particles continuously at a safe distance; this would avoid the necessity of having a spacecraft fly through a target cloud such as a comet tail. If properly designed and implemented, a laser-based optical trapping system could fundamentally change the way scientists designand implement NASA missions that require mass spectroscopy and particle collection.

Laser↗
NASA NTRS1994

Making Rectangular Apertures In Silicon

Conventional silicon micromachining techniques produce micrometer-sized rectangular apertures. Used to define source and detector openings for measurements of images and scattered light in visible, ultraviolet, and soft x-ray wavelength regions, and as general-purpose optical slits or slit arrays. Rectangular microscopic apertures replace circular pinholes made by puncturing foils with needles or by drilling foils with intense, highly-focused laser beams. Precise photolithography yields apertures of superior geometry.

Leviton, Douglas B.↗
NASA NTRS1977

In-situ laser retorting of oil shale

Oil shale formations are retorted in situ and gaseous hydrocarbon products are recovered by drilling two or more wells into an oil shale formation underneath the surface of the ground. A high energy laser beam is directed into the well and fractures the region of the shale formation. A compressed gas is forced into the well that supports combustion in the flame front ignited by the laser beam, thereby retorting the oil shale. Gaseous hydrocarbon products which permeate through the fractured region are recovered from one of the wells that were not exposed to the laser system.

Bloomfield, H. S.↗
DOE OSTI2023

Laser Welder Startup Capacitor Failure Analysis & Suggested Potential Mitigation Factors [Slides]

On the morning of the failure (Mon 2/23/2023 5 AM), an unclassified Yttrium Aluminum Garnet Laser Welder system was working within operational parameters. However, when another part was positioned for drilling and it was activated, the coolant compressor was heard shutting off by everyone working on the laser. The coolant pump reportedly failed due to blown 5-amp fuses. Since the coolant pump was offline, the laser was automatically placed into an inoperable state. Failure of the coolant pump was due to a failed capacitor in the startup circuit for the pump.

42 ENGINEERING↗
DOE OSTI2021

Evaluation of Microhole Drilling Technology for Geothermal Exploration, Assessment, And Monitoring

One of the greatest barriers to geothermal energy expansion is the high cost of drilling during exploration, assessment, and monitoring. Microhole drilling technology—small-diameter 2–4 in. (~5.1–10.2 cm) boreholes—is one potential low-cost alternative for monitoring and evaluating bores. However, delivering high weight-on-bit (WOB), high torque rotational horsepower to a conventional drill bit does not scale down to the hole sizes needed to realize the cost savings. Coiled tube drilling technology is one solution, but these systems are limited by the torque resistance of the coil system, helical buckling in compression, and most of all, WOB management. The evaluation presented herein will: (i) evaluate the technical and economic feasibility of low WOB technologies (specifically, a percussive hammer and a laser-mechanical system), (ii) develop downhole rotational solutions for low WOB drilling, (iii) provide specifications for a low WOB microhole drilling system, (iv) implement WOB control for low WOB drilling, and (v) evaluate and test low WOB drilling technologies.

15 GEOTHERMAL ENERGY↗
NASA NTRS2011

Downhole Elemental Analysis with LIBS

In this paper we discuss a novel instrument, currently under development at Honeybee Robotics with SBIR funding from NASA. The device is designed to characterize elemental composition as a function of depth in non-terrestrial geological formations. The instrument consists of a miniaturized laser-induced breakdown spectrometer (LIBS) analyzer integrated in a 2" diameter drill string. While the drill provides subsurface access, the LIBS analyzer provides information on the elemental composition of the borehole wall. This instrument has a variety of space applications ranging from exploration of the Moon for which it was originally designed, to Mars, as well as a variety of terrestrial applications. Subsurface analysis is usually performed by sample acquisition through a drill or excavator, followed by sample preparation and subsequent sample presentation to an instrument or suite of instruments. An alternative approach consisting in bringing a miniaturized version of the instrument to the sample has many advantages over the traditional methodology, as it allows faster response, reduced probability of cross-contamination and a simplification in the sampling mechanisms. LIBS functions by focusing a high energy laser on a material inducing a plasma consisting of a small fraction of the material under analysis. Optical emission from the plasma, analyzed by a spectrometer, can be used to determine elemental composition. A triangulation sensor located in the sensor head determines the distance of the sensor from the borehole wall. An actuator modifies the position of the sensor accordingly, in order to compensate for changes due to the profile of the borehole walls. This is necessary because LIBS measurements are negatively affected by changes in the relative position of the focus of the laser with respect to the position of the sample (commonly referred to as the "lens to sample distance"). Profiling the borehole is done by adjusting the position of the sensor with a vertical stage; a second actuator at the top of the downhole probe allows radial scanning of the borehole. Analysis of iron and titanium in lunar simulant with LIBS was performed in air using the method of standard addition. The results for lunar simulant NU-LHT-2M show a value for the concentration of iron ranging between 2.29% and 3.05% depending on the atomic line selected. The accepted value for the sample analyzed is 2.83%, showing the capability for the system in development to provide qualitative and semi-quantitative analysis in real-time.

Moreschini, Paolo↗
NASA NTRS1989

Laser-powered Martian rover

Two rover concepts were considered: an unpressurized skeleton vehicle having available 4.5 kW of electrical power and limited to a range of about 10 km from a temporary Martian base and a much larger surface exploration vehicle (SEV) operating on a maximum 75-kW power level and essentially unrestricted in range or mission. The only baseline reference system was a battery-operated skeleton vehicle with very limited mission capability and range and which would repeatedly return to its temporary base for battery recharging. It was quickly concluded that laser powering would be an uneconomical overkill for this concept. The SEV, on the other hand, is a new rover concept that is especially suited for powering by orbiting solar or electrically pumped lasers. Such vehicles are visualized as mobile habitats with full life-support systems onboard, having unlimited range over the Martian surface, and having extensive mission capability (e.g., core drilling and sampling, construction of shelters for protection from solar flares and dust storms, etc.). Laser power beaming to SEV's was shown to have the following advantages: (1) continuous energy supply by three orbiting lasers at 2000 km (no storage requirements as during Martian night with direct solar powering); (2) long-term supply without replacement; (3) very high power available (MW level possible); and (4) greatly enhanced mission enabling capability beyond anything currently conceived.

Harries, W. L.↗
DOE OSTI2023

Laser ultrasonic imaging of subsurface defects with the linear sampling method

Laser ultrasonics is a remote nondestructive evaluation technique suitable for real-time monitoring of fabrication processes in semiconductor metrology, advanced manufacturing, and other applications where non-contact, high fidelity measurements are required. Here we investigate laser ultrasonic data processing approaches to reconstruct images of subsurface side drilled holes in aluminum alloy specimens. We demonstrate through simulation that the model-based linear sampling method (LSM) can perform accurate shape reconstruction of single and multiple holes and produce images with well-defined boundaries. We experimentally confirm that LSM produces images that represent the internal geometric features of an object, some of which may be missed by conventional imaging.

42 ENGINEERING↗
DOE OSTI2019

EGS Collab Testbed 2: Laser Scanned 4100 L Drift Map

The EGS Collab project is evaluating a site for Experiment 2 (hydraulic fracturing/shearing) at a depth of 1.25 km in the Sanford Underground Research Facility (SURF) on the 4100 Level. Two early test holes were drilled in an alcove (formerly known as Battery Charging Station) near Yates Shaft. Recently, we conducted a laser survey around the Testbed 2 to capture the details of the drift. This submission package includes the laser scanned drift map around the Testbed 2. The drift map data are presented in AutoCAD (*dxf), Leapfrog mesh (*.msh), and point cloud (*.csv) file formats. Note: The coordinate system used is local Homestake Mine Coordinate (HMC) system from an old gold mine that was in operation for over 100 years.

15 GEOTHERMAL ENERGY↗
NASA NTRS2014

In Situ Geochronology on the Mars 2020 Rover with KArLE (Potassium-Argon Laser Experiment)

If extinct and/or extant life is discovered on Mars, knowledge of the chronology of the biosphere will be of paramount importance. KArLE will provide absolute ages of Mars 2020 rocks, which will allow us to understand them in the context of Mars' geologic history, connect them to other landing sites, and compare Martian epochs of habitability with the Earth's history and evolution of life. KArLE significantly enhances the ability of Mars 2020 to meet its science objectives by performing in situ age dating on key lithologies, enabling targeted searches for ancient biosignatures and increasing the chances of identifying evidence for Martian microbial life. The KArLE investigation makes its measurements on a core sample obtained with the rover drill, inserted into a small, mechanically simple chamber, followed by interrogation by laser-induced breakdown spectroscopy (LIBS), mass spectrometry, and optical imaging. The KArLE experiment is flexible enough to accommodate any partner providing these instrument components, a creative approach that extends the ability of the Mars 2020 payload to accomplish an additional highly-desirable science measurement for low cost and risk and minimal extra hardware.

Cohen, B. A.↗
NASA NTRS1989

Laser Technology

Amoco Laser Company, a subsidiary of Amoco Corporation, has developed microlasers for the commercial market based on a JPL concept for optical communications over interplanetary distances. Lasers emit narrow, intense beams of light or other radiation. The beams transmit communication signals, drill, cut or melt materials or remove diseased body tissue. The microlasers cover a broad portion of the spectrum, and performance is improved significantly. Current applications include medical instrumentation, color separation equipment, telecommunications, etc.

Source record↗