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DOE OSTI2022

Design of inertial fusion implosions reaching the burning plasma regime

One of the last remaining milestones in fusion research before reaching ignition is creating a burning plasma state, where alpha particles from deuterium-tritium (DT) fusion reactions redeposit their energy as the dominant source of heating in the plasma. The indirect-drive inertial confinement fusion approach at the National Ignition Facility (NIF) uses a laser-generated radiation cavity (hohlraum) to spherically implode DT fuel to high temperatures and densities in a central ”hot spot”. Here, we deliver more energy to the hot spot than ever before, while maintaining the extreme pressures required for inertial confinement, by increasing the size of the implosion compared to previous experiments. We develop more efficient hohlraums, to drive these larger implosions within NIF’s current laser energy and power capability and control symmetry by moving energy between laser beams and by changing the shape of the hohlraum. These designs resulted in record fusion powers of 1.5 petawatts, greater than the input power of the laser, and 170 kJ of fusion energy. Radiation hydrodynamics simulations show alpha particle heating as the dominant term in the hot spot energy balance, e.g. a burning plasma state. This work is expected to motivate future studies of burning plasmas and improve predictive capability by providing a benchmark for modeling used to understand the proximity to ignition.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Determining processing behaviour of pure Cu in laser powder bed fusion using direct micro-calorimetry

We report copper is challenging to process by laser powder bed fusion (LPBF) given its high reflectivity at common infrared laser diode wavelengths and high thermal conductivity. Successful deposition of copper in a predictable and repeatable fashion relies on understanding the development of the keyhole melting regime, as well as heating, melting, boiling and vapour formation behaviour when interacting with a laser beam within an LPBF environment. In this study, in situ optical absorptivity measurements are used to clarify the complex physics of the laser material interaction. Absorptivity of laser energy is measured using direct micro-calorimetry and compared to melt pool depth in correlation to processing parameters. The measured absorptivity for a 100 μm layer thickness of powder was found to be approximately four times higher than that of the bare polished discs. It was also shown that high laser power above 500 W and scan speed up to 150 mm/s are appropriate for effective melting of the powder layer, with these parameters overcoming the threshold required to achieve keyhole melting. This is explained by multiple reflections withing the powder particles and the lower thermal conductivity of packed powder in comparison to bare discs. Melt pool formation was found to be highly unstable and an explosive behavior was observed when in the keyhole regime, caused by high fluctuations in absorptivity values. This work demonstrates calorimetry can be used to monitor melting behaviour in a real-time fashion during processing for this challenging to process material, thereby avoiding unnecessary parametric optimisation. In addition, the parametric window for optimum processing revealed here can inform future work.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Rapid cooling of the in-plane motion of two-dimensional ion crystals in a Penning trap to millikelvin temperatures

Here, we propose a highly feasible technique with no experimental overhead to rapidly cool the in-plane degrees of freedom of large two-dimensional ion crystals in Penning traps. Through simulations, we demonstrate that our approach enables the in-plane modes to cool down to a temperature of around 1 mK in less than 10 ms. Our technique relies on near-resonant coupling of the poorly cooled in-plane motions and the efficiently cooled out-of-plane motions, and is achieved without introducing additional potentials. The rapid cooling enabled by our approach is in contrast to typical operating conditions, where our simulations of the laser cooling dynamics suggest that the ion crystal's in-plane motion cools very slowly on a timescale of several hundreds of milliseconds, a rate likely slower than experimental heating rates. Our work sets the stage for sub-Doppler laser cooling of the planar motion, and more robust and versatile quantum simulation and quantum sensing experiments with two-dimensional crystals in Penning traps.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Thermal Management of Discretized Heaters Using CuW Microchannel Heat Sinks and FC3283

Single-phase cooling using microchannel heat sinks (MCHS) has become a popular approach for overcoming the thermal challenges associated with high-powered microelectronic devices. Thermal management is one of the largest barriers to higher power densities in electronics and frequently limits overall device performance. The implementation of forced convective cooling via single-phase liquid cooling in MCHS reduces the thermal resistance resulting in lower device temperatures at high-power conditions, which can decrease the package size and extend the lifespan of devices. The goal of the work described in this article was to investigate practical cooling solutions for laser diode bars. This study examined the effectiveness of a copper tungsten (CuW) microchannel heat sink paired with a dielectric coolant (FC3283) for dissipating both discrete and uniform heat fluxes up to 600 W/cm2 across a 0.25-cm2 surface area through a numerical and experimental study. CuW was chosen as the MCHS material because it is thermal expansion matched to GaAs, which is a common laser diode substrate. FC3283 serves as a dielectric coolant that is compatible with power electronics cooling. The microchannels utilized in this work were approximately $365$ $μ$ m deep and $100$ $μ$ m wide resulting in a hydraulic diameter of $160$ $μ$ m. The study investigated the cooling performance across a variety of applied power loads and flow rates to determine optimal effectiveness. The resulting thermal resistance ranged from 0.15 cm2 K/W at the highest flow rate to 0.26 cm2 K/W at the lowest flow rate. Further, the resulting thermal performance from this study demonstrates the importance of considering discrete heat sources separately from uniform heat sources and proved that the unique combination of CuW microchannels with FC3283 can be a promising cooling option toward future advancements of laser diode bars and other high-power microelectronics.

42 ENGINEERING↗

DOE OSTI2026

Direct measurement of electron heating in electron-only reconnection in a laboratory mini-magnetosphere

We report on the experimental observation of electron heating in electron-only magnetic reconnection in laser-driven laboratory mini-magnetosphere on the Large Plasma Device (LAPD) at the University of California, Los Angeles. In this experiment, a fast-flowing plasma impacts a pulsed magnetic dipole embedded within LAPD’s magnetized ambient plasma, creating an ion-scale magnetosphere and driving electron-only magnetic reconnection between the background and dipole field lines. The electron velocity distribution is measured across the reconnection region using noncollective Thomson scattering, enabling determination of electron temperature and density. Significant electron heating is observed in the electron diffusion region, increasing from an initial temperature of 1.8 to 9.5 eV, corresponding to a 40% local conversion of Poynting flux into electron enthalpy flux. Particle-in-cell simulations that provide insights into the heating mechanisms are also presented.

Rovige, Lucas [Department of Physics and Astronomy↗

DOE OSTI2024

InP- and GaAs-Based 0.6 eV GaInAs Devices for Thermophotovoltaics and Laser Power Conversion

Emerging applications such as thermal energy grid storage, waste heat recovery and portable power generation require efficient thermophotovoltaic (TPV) converters tuned to temperatures near 1000 Degrees Celsius or below. Metamorphic GaInAs with larger lattice constants than InP present a promising option for these needs. The ability to grow these devices on GaAs substrates instead of more expensive InP would enhance the scalability of these devices. In this talk, we present inverted metamorphic Ga0.3In0.7As photovoltaic converters with sub-0.60 eV bandgaps grown on InP and GaAs substrates. These devices are realized using InAsP or GaInP/InAsP compositionally graded buffers which exhibit threading dislocation densities of 1.3 +/- 0.6 x 106 cm-2 and 8.9 +/- 1.7 x 106 cm-2 on InP and GaAs, respectively. Despite this difference in defect density, the devices generate similar open-circuit voltages of 0.386 V and 0.383 V, respectively, under irradiance producing a short-circuit current density of -10 A/cm2, with bandgap-voltage offsets of 0.20 and 0.21 V. We estimate their thermophotovoltaic efficiency using these measurements coupled with broadband reflectance measurments. The InP-based cell is estimated to yield 1.09 W/cm2 at 1100 Degrees Celsius vs. 0.92 W/cm2 for the GaAs-based cell, with TPV efficiencies of 16.8 vs. 9.2%. Both devices are limited by sub-bandgap absorption, which we assess largely occurs in the graded buffers. We estimate that the 1100 Degrees Celsius thermophotovoltaic efficiencies would increase to 24.0% and 20.7% in structures with the graded buffer removed, if previously demonstrated reflectance is achieved. These devices also have application as laser power converters in the 2.0-2.3 um atmospheric window. We estimate efficiencies of 36.8% and 32.5% under 2.0 um monochromatic irradiance of 1.86 W/cm2 and 2.81 W/cm2, respectively.

ENGINEERING,MATERIALS SCIENCE,SOLAR ENERGY↗

DOE OSTI2022

Optical diagnostics of laser-produced plasmas

Laser-produced plasmas (LPPs) engulf exotic and complex conditions ranging in temperature, density, pressure, magnetic and electric fields, charge states, charged particle kinetics, and gas-phase reactions, based on the irradiation conditions, target geometries, and the background cover gas. The application potential of the LPP is so diverse that it generates considerable interest for both basic and applied research areas. The fundamental research on LPPs can be traced back to the early 1960s, immediately after the invention of the laser. In the 1970s, the laser was identified as a tool to pursue inertial confinement fusion, and since then, several other technologies emerged out of LPPs. These applications prompted the development and adaptation of innovative diagnostic tools for understanding the fundamental nature and spatiotemporal properties of these complex systems. Although most of the traditional characterization techniques developed for other plasma sources can be used to characterize the LPPs, care must be taken to interpret the results because of their small size, transient nature, and inhomogeneities. The existence of the large spatiotemporal density and temperature gradients often necessitates non-uniform weighted averaging over distance and time. Among the various plasma characterization tools, optical-based diagnostic tools play a key role in the accurate measurements of LPP parameters. The optical toolbox contains optical spectroscopy (emission, absorption, and fluorescence), passive and active imaging and optical probing methods (shadowgraphy, Schlieren, interferometry, Thomson scattering, deflectometry, and velocimetry). Each technique is useful for measuring a specific property, and its use is limited to a certain time span during the LPP evolution because of the sensitivity issues related to the selected measuring tool. Therefore, multiple diagnostic tools are essential for a comprehensive insight into the entire plasma behavior. In recent times, the improvements in performance in the lasers and detector systems expanded the capability of the aforementioned passive and active diagnostics tools. Furthermore, this review provides an overview of optical diagnostic tools frequently employed for the characterization of the LPPs and emphasizes techniques, associated assumptions, and challenges. Considering most of the industrial and other applications of the LPP belong to low to moderate laser intensities (10 8 – 10 15 Wcm –2 ), this review focuses on diagnostic tools pertaining to this regime.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Nonlocal effects on thermal transport in hydrodynamic simulations of unmagnetized MagLIF-relevant gaspipes on NIF

We present simulations of heat flow relevant to gaspipe experiments on the National Ignition Facility to investigate kinetic effects on transport phenomena. D 2 and neopentane (C 5 H 12 ) filled targets are used to study the laser preheat stage of a MagLIF scheme where an axial magnetic field is sometimes applied to the target. Simulations were done with the radiation-MHD code HYDRA with a collision-dominated fluid model and the SNB nonlocal electron thermal conduction model. Using the SNB model to evolve the electron temperature increased the heat front propagation of neopentane gas targets compared to a local model by limiting radial heat flow. This increases electron temperature near the axis, which decreases laser absorption. We find that the effect of heat flow models on temperature profiles and laser propagation is modest. Beyond the SNB model, we utilize HYDRA to initialize plasma conditions for the Vlasov–Fokker–Planck K2 code. We run K2 until a quasi-steady state is reached and examine the impact of kinetic effects on heat transport. Although axial heat flow is well predicted by fluid models, the fluid model consistently overpredicts radial heat flow up to 150% in regions with the largest temperature gradient of D 2 filled gaspipes. On the other hand, the SNB nonlocal electron conduction model is found to be adequate for capturing kinetic heat flow in gaspipes.

Lau, Ryan Y. [Univ. of Colorado, Boulder, CO (Unit↗

DOE OSTI2022

Diffraction and thermal effect of a Bessel-Gaussian laser for Ag nanoparticle deposition

Nanoparticles are known to sinter at much lower temperatures than the corresponding bulk or micro size particles. A laser-assisted sintering process is considered in this study to sinter Ag nanoparticles by dispensing Ag paste onto an indium tin oxide-coated Si substrate. The Gaussian beam of a CO 2 laser source is propagated through axicon and biconvex lenses, and the resulting hollow beam is focused on the Ag paste with a hollow parabolic mirror. A Bessel-Gaussian irradiance distribution is obtained at the focal plane of the parabolic mirror due to the interference of the hollow laser cone. The Fresnel diffraction approximation is considered to determine the phasor of the laser and an analytical approach is implemented to calculate the irradiance distribution of the Bessel-Gaussian beam. This irradiance distribution is utilized as a heat source in a heat conduction model and the temperature distribution is analyzed for thin Ag films formed during the laser sintering of Ag nanoparticles. An analytical expression is obtained for the temperature distribution by solving the heat conduction equation using Fourier transform for finite media. The widths of the deposited Ag lines are predicted from the temperature profiles and the model predictions compare well with the experimental results. The isotherms are found to be geometrically noncongruent with convex and concave tips depending on the locally maximum and minimum irradiances of the Bessel-Gaussian beam, respectively. The convex and concave tips, however, appear in the same isotherm for sufficiently high substrate speed relative to the laser beam.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2020

Multiplexable high-temperature stable and low-loss intrinsic Fabry-Perot in-fiber sensors through nanograting engineering

This paper presents a method of using femtosecond laser inscribed nanograting as low-loss– and high-temperature–stable in-fiber reflectors. By introducing a pair of nanograting inside the core of a single-mode optical fiber, an intrinsic Fabry-Perot interferometer can be created for high-temperature sensing applications. The morphology of the nanograting inscribed in fiber cores was engineered by tuning the fabrication conditions to achieve a high fringe visibility of 0.49 and low insertion loss of 0.002 dB per sensor. Using a white light interferometry demodulation algorithm, we demonstrate the temperature sensitivity, cross-talk, and spatial multiplexability of sensor arrays. Both the sensor performance and stability were studied from room temperature to 1000°C with cyclic heating and cooling. Our results demonstrate a femtosecond direct laser writing technique capable of producing highly multiplexable in-fiber intrinsic Fabry-Perot interferometer sensor devices with high fringe contrast, high sensitivity, and low-loss for application in harsh environmental conditions.

Wang, Mohan (ORCID:0000000166784993)↗

DOE OSTI2024

Influence of alloy solidification path on melt pool behavior in additive manufacturing

Numerical models used to study transport phenomena in laser-powder bed fusion processes often rely on assumptions and simplifications to reduce their computational expense. One common simplification is in the description of latent heat evolution during the solid-liquid phase change (i.e., the solidification pathway), justified by the fact that the mushy zone thickness is similar to the numerical grid spacing used for continuum transport models. The lack of resolution of transport phenomena in the mushy zone motivates the use of computationally convenient solidification paths such as linear or sigmoidal relationships over pathways derived from fundamental solidification theory such as equilibrium or Scheil models. In the present work, an uncertainty quantification (UQ) framework is used to analyze the influence of solidification pathway selection on the solidification dynamics and melt pool geometries in laser based additive manufacturing (AM) of IN625. Results show the solidification pathway has a quantifiable influence on the cooling rate at the liquidus isotherm, mushy zone thickness, and solidification time. Due to similarities in the latent heat evolution at the beginning of solidification, the equilibrium and Scheil models predict similar cooling rates near the liquidus isotherm, however the wider freezing range of Scheil leads to a wider mushy zone compared to equilibrium. The non-physical latent heat release profiles of sigmoidal and linear paths lead to significant overpredictions of cooling rates at the liquidus isotherm compared to equilibrium and Scheil. Finally, these results indicate that careful consideration should be given to the choice of solidification pathway to ensure reliable model predictions.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Nanoscale reshaping of resonant dielectric microstructures by light-driven explosions

Femtosecond-laser-assisted material restructuring employs extreme optical intensities to localize the ablation regions. To overcome the minimum feature size limit set by the wave nature of photons, there is a need for new approaches to tailored material processing at the nanoscale. Here, we report the formation of deeply-subwavelength features in silicon, enabled by localized laser-induced phase explosions in prefabricated silicon resonators. Using short trains of mid-infrared laser pulses, we demonstrate the controllable formation of high aspect ratio (>10:1) nanotrenches as narrow as ~ $λ / 80$. The trench geometry is shown to be scalable with wavelength, and controlled by multiple parameters of the laser pulse train, such as the intensity and polarization of each laser pulse and their total number. Particle-in-cell simulations reveal localized heating of silicon beyond its boiling point and suggest its subsequent phase explosion on the nanoscale commensurate with the experimental data. The observed femtosecond-laser assisted nanostructuring of engineered microstructures (FLANEM) expands the nanofabrication toolbox and opens exciting opportunities for high-throughput optical methods of nanoscale structuring of solid materials.

42 ENGINEERING↗

DOE OSTI2023

3D Printing of Solar Absorber Tube with Internal/External Structures for Heat Transfer Enhancement and Temperature Leveling using Additive Manufacturing Technology

In this project, to tackle the technical obstacles, we utilized Laser Additive Alloying (LAA), an additive manufacturing (AM) technology, to 3D print the entire absorber tube with optimized helical fins to improve heat transfer at the expense of minimized pressure drop increase. The 3D printed absorber tubes can increase the uniformity of circumferential temperature distribution, reduced the thermal stresses, decrease the heat loss, and reach the target receiver thermal efficiency.

14 SOLAR ENERGY↗

DOE OSTI2022

Ambient-temperature liquid jet targets for high-repetition-rate HED discovery science

High-power lasers can generate energetic particle beams and astrophysically relevant pressure and temperature states in the high-energy-density (HED) regime. Recently-commissioned high-repetition-rate (HRR) laser drivers are capable of producing these conditions at rates exceeding 1 Hz. However, experimental output from these systems is often limited by the difficulty of designing targets that match these repetition rates. To overcome this challenge, we have developed tungsten microfluidic nozzles, which produce a continuously replenishing jet that operates at flow speeds of approximately 10 m/s and can sustain shot frequencies up to 1 kHz. The ambient-temperature planar liquid jets produced by these nozzles can have thicknesses ranging from hundreds of nanometers to tens of micrometers. In this work, we illustrate the operational principle of the microfluidic nozzle and describe its implementation in a vacuum environment. Further, we provide evidence of successful laser-driven ion acceleration using this target and discuss the prospect of optimizing the ion acceleration performance through an in situ jet thickness scan. Future applications for the jet throughout HED science include shock compression and studies of strongly heated nonequilibrium plasmas. When fielded in concert with HRR-compatible laser, diagnostic, and active feedback technology, this target will facilitate advanced automated studies in HRR HED science, including machine learning-based optimization and high-dimensional statistical analysis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Neutron yield enhancement and suppression by magnetization in laser-driven cylindrical implosions

In inertial confinement fusion, an externally applied magnetic field can reduce heat losses in the compressing fuel thereby increasing neutron-averaged ion temperatures and neutron yields. Yet, magnetization is only beneficial if the magnetic pressure remains negligible compared to the fuel pressure. Experiments and three-dimensional magneto-hydrodynamic simulations of cylindrical implosions on the OMEGA laser show ion temperature and neutron yield enhancements of up to 44% and 67%, respectively. As the applied, axial magnetic field is increased to nearly 30T, both experiments and simulations show yield degradation. For magnetized, cylindrical implosions, there exists an optimal magnetic field that maximizes the increase in yield. Limiting the fuel convergence ratio by preheating the fuel can further increase the benefit of magnetization. The findings demonstrate that it is possible to create a plasma with a density of order 1 g/cm 3 and an ion temperature greater than 1 keV with a magnetic pressure comparable to the thermal pressure, a new regime for laser-produced plasmas on OMEGA.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Process–Property–Performance Mapping of Additively Manufactured 316H Stainless Steel Components

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development of advanced materials and components fabricated via additive manufacturing, and is using laser powder bed fusion (LPBF) of 316H stainless steel as an initial case study. In the previous fiscal year, miniature high-throughput specimens were printed on multiple LPBF systems to provide initial processing windows to minimize porosity and limit epitaxial grain growth during prints. This fiscal year, scaled builds were completed on three different LPBF systems at ORNL: a GE Concept Laser M2, a Renishaw AM400, and an EOS M290. Builds on the Concept Laser were conducted on multiple powder lots and processing parameter ranges to provide microstructure effects on time-independent and time-dependent mechanical properties. Builds on the Renishaw were produced using Oak Ridge National Laboratory (ORNL)-optimized printing parameters and Argonne National Laboratory (ANL)-optimized printing parameters to compare outcomes of parallel process optimization efforts at different national laboratories on the same LPBF system. Similarly, the build completed on the EOS M290 replicated the processing parameters of builds completed at Los Alamos National Laboratory (LANL). Optical microscopy and electron backscatter diffraction characterization was completed on all builds. In addition to the general round robin characterization, this work-package generated time-independent data, including tensile and fracture toughness test data on scaled Concept Laser builds as a function of processing parameters and post-build heat treatment. This analysis is complimentary to work in parallel work packages aiming to establish heat treatment and processing effects on time-dependent properties. It was found that although the stress-relief heat treatment provides the highest strength at lower-temperatures, tensile strength begins to converge at higher temperatures regardless of heat treatment condition. In addition, the more rigorous solution annealing and hot-isostatic pressing post-build heat treatments result in higher fracture toughness than the stress-relieved condition. The root-causes of the lower fracture toughness of the stress-relieved LPBF 316H material was informed via a stress-relief optimization study on a scaled concept laser print, where it was found that although dislocation recovery was largely complete after only a couple hours at 650°C, the extended hold of the current 24h heat treatment employed on scaled builds likely caused increased carbide volume fractions along the LPBF 316H grain boundaries, thereby deteriorating crack propagation resistance. This trend was seen to become more deleterious with additional increases of stress-relief temperature to 750°C or 850°C. These results have helped inform a new optimal stress-relief annealing condition for LPBF 316H for future campaign testing (650°C for 2h).

36 MATERIALS SCIENCE↗

DOE OSTI2024

Process–Property–Performance Mapping of Additively Manufactured 316H Stainless Steel Components

36 MATERIALS SCIENCE↗

DOE OSTI2022

Using post-processing heat treatments to elucidate precipitate strengthening of additively manufactured superalloy 718

The poor machinability and extensive work hardening of Ni-based superalloys makes additive manufacturing an attractive option for producing geometrically complex components with distinct microstructures. Although previous studies show recovery of high strength at room temperature, very few studies demonstrate successful properties at elevated temperatures required for industrial applications. Here, the objectives of this study are to present a post-build heat treatment for high strength across a wide temperature range, determine the strength contribution of nanoscale precipitating phases to the overall mechanical properties of superalloy 718, and from these, provide a comprehensive microstructure-property relationship for wrought and AM 718 to guide efforts to simulate the properties of AM components. Laser powder bed fusion–produced superalloy 718 was characterized at multiple length scales using scanning electron microscopy and transmission electron microscopy in the as-built condition and with multiple heat treatments designed to form combinations of γ', γ", and δ precipitates. Uniaxial tensile tests performed from room temperature to 600 °C on subsize specimens determined the yield strength, elastic modulus, ultimate tensile strength, fracture stress, and uniform elongation. Precipitates in this work proved to be weak barriers to dislocation motion through a dispersed barrier model, but they provided strength to the alloy through their consistent high density. The relative contribution to the yield strength from γ" remained consistent between 48% and 57% of the total strength up to 600 °C, the primary influence on the high temperature strength of superalloy 718. The strength factors for γ" and δ precipitates were found to trend inversely with tensile test temperature and may be attributable to the differences in precipitate coherency. A post-build heat treatment is recommended to maintain high strength at elevated temperatures. A quantitative microstructure-property relationship, dependent on precipitate size, density, and morphology, was derived and can estimate the yield strength across a wide temperature range applicable to the operational regimes for superalloy 718.

36 MATERIALS SCIENCE↗