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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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Holographic LIDAR telescope includes holographic disk, rotation of which sweeps collimated, monochromatic beam of light from laser through conical scan. Holographic disk diffracts light scattered back from target volume or area to focal point located at stationary photomultiplier detector. Two conical baffles prevent stray light from reaching detector.
A very precise 6.7- by 6.7-m planar near-field scanner has recently become operational at the NASA Lewis Research Center. The scanner acquires amplitude and phase data at discrete points over a vertical rectangular grid. During the design phase for this scanner, special emphasis was given to the dimensional stability of the structures and the ease of adjustment of the rails that determine the accuracy of the scan plane. A laser measurement system is used for rail alignment and probe positioning. This has resulted in very repeatable horizontal and vertical motion of the probe cart and hence precise positioning in the plane described by the probe tip. The resulting accuracy will support near-field measurements at 60 GHz without corrections. Subsystem design including laser, electronic and mechanical and their performance is described. Summary data are presented on the scan plane flatness and environmental temperature stability. Representative near-field data and calculated far-field test results are presented. Prospective scanner improvements to increase test capability are also discussed.
The multi-beam long trace profiler (LTP) under development at NASA s Marshall Space Flight Center[1] is designed to increase the efficiency of metrology of replicated X-ray optics. The traditional LTP operates on a single laser beam that scans along the test surface to detect the slope errors. While capable of exceptional surface slope accuracy, the LTP single beam scanning has slow measuring speed. As metrology constitutes a significant fraction of the time spent in optics production, an increase in the efficiency of metrology helps in decreasing the cost of fabrication of the x-ray optics and in improving their quality. Metrology efficiency can be increased by replacing the single laser beam with multiple beams that can scan a section of the test surface at a single instance. The increase in speed with such a system would be almost proportional to the number of laser beams. A collaborative feasibility study has been made and specifications were fixed for a multi-beam long trace profiler. The progress made in the development of this metrology system is presented.
Here, this paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects. 304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size. Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part. To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.
The elastic-wave scattering at interfaces, such as cracks, is essential for nondestructive inspections, and hence, understanding the phenomenon is crucial. However, the elastic-wave scattering at cracks is very complex in three dimensions since microscopic asperities of crack faces can be multiple scattering sources. We propose a method for exploring 3D elastic-wave scattering based on our previously developed high-resolution 3D phased-array system, the piezoelectric and laser ultrasonic system (PLUS). We describe the principle of PLUS, which combines a piezoelectric transmitter and a 2D mechanical scan of a laser Doppler vibrometer, enabling us to resolve a crack into a collection of scattring sources. Subsequently, we show how the 3D elastic-wave scattering in the vicinity of each response can be extracted. Here, we experimentally applied PLUS to a fatigue-crack specimen. We found that diverse 3D elastic-wave scattering occurred in a manner depending on the responses within the fatigue crack. This is significant because access to such information will be useful for optimizing inspection conditions, designing ultrasonic measurement systems, and characterizing cracks. More importantly, the described methodology is very general and can be applied to not only metals but also other materials such as composites, concrete, and rocks, leading to progress in many fields.
A magnetic recording and magneto-optic playback system is disclosed wherein thermomagnetic recording is employed. A transparent isotropic film is heated along a continuous path by a focused laser beam. As each successive area of the path is heated locally to the vicinity of its Curie point in the presence of an applied magnetic field, a magneto-optic density is established proportional to the magnetic field and fixed in place as the area cools once the laser beam moves on to an adjacent area. To play back the recorded data, the intensity of the laser beam is reduced to avoid reaching the vicinity of the Curie point of the film as it is scanned by the laser beam in the same manner as for recording. A Faraday effect analyzer and photo detector are employed as a transducer for producing an output signal.
Abstract The design and fabrication of Inconel 718 open-pore lattice structures via Laser Powder Bed Fusion (LPBF) has been investigated in this research, focusing on applications such as catalyst supports in jet fuel production. The study explores the impact of laser power and scanning speed on the geometrical resolution of these structures aiming to achieve high porosity (porosity > 60%) and specific pore sizes ranging from 500–1000 μm, intending to serve as catalyst supports, replacing conventionally manufactured foams to reduce costs. Results demonstrate the significant influence of processing parameters on the geometrical aspects of printed lattice structures, with laser power having a more pronounced effect on geometrical accuracy than scanning speed. Additionally, the mechanical properties of the printed lattice structures showed a correlation with the lattice strut sizes, as lattices with less porosity and thicker struts resulted in higher maximum shear stress.
Biomimetic model organisms could be useful surrogates for live animals in many applications if the models have sufficient biofidelity. One such application is for use in field and laboratory tests of fish mortality associated with passage through hydropower turbines. Laboratory trials suggest that blade strikes are especially injurious and often causes mortality when fish are struck by thinner blades moving at higher velocities. Dose-response relationships have been created from these data, but the exact relationship between fish mortality and the actual forces enacted on fish during simulated blade strike testing remains unknown. Here, we describe the methods used to create a prototype biomimetic model fish composed of ballistic gelatin and covered with a surrogate skin to better approximate the biomechanical properties of a fish body. Frozen fish were scanned with high-fidelity laser scanners, and a 3D-printed, reusable mold was created from which to cast our gelatin model. Computed tomography scan data, imaged directly or taken from online data repositories, were also successfully used to create CAD models for use in additive manufacturing of molds. One 3-axis accelerometer was embedded into the gelatin to compare accelerometer data to dose-response data from previous laboratory research on live fish. The resulting model ( i.e. , Gelfish) had a statistically indistinguishable tissue durometer to that of real fish tissue and preliminary blade strike impact testing suggested its overall flexibility was similar to that of live fish. Gelfish was designed with biofidelity as its guiding principle and our results suggest initial experimentation was successful. Future research will include replication of initial Gelfish test results, quantitative measurement of model flexibility relative to real fish, and inclusion of surrogate skeletal structures to enhance biofidelity. Use of more sophisticated sensors would also better quantify the physical forces of blade strike impact and help determine how said forces correlate with rates of mortality observed during tests on live fish.
Abstract The design and fabrication of Inconel 718 open-pore lattice structures via Laser Powder Bed Fusion (LPBF) has been investigated in this research, focusing on applications such as catalyst supports in jet fuel production. The study explores the impact of laser power and scanning speed on the geometrical resolution of these structures aiming to achieve high porosity (porosity > 60%) and specific pore sizes ranging from 500–1000 μm, intending to serve as catalyst supports, replacing conventionally manufactured foams to reduce costs. Results demonstrate the significant influence of processing parameters on the geometrical aspects of printed lattice structures, with laser power having a more pronounced effect on geometrical accuracy than scanning speed. Additionally, the mechanical properties of the printed lattice structures showed a correlation with the lattice strut sizes, as lattices with less porosity and thicker struts resulted in higher maximum shear stress.
This paper introduces the new Portable Laser Guided Robotic antenna range (PLGR) at the National Aeronautics and Space Administration's (NASA) Glenn Research Center. Previous work used industrial robots in fixed facilities to characterize antennas and required fixtures that do not lend themselves to portable applications.NASA's PLGR system is designed for in-situ antenna measurements at a remote site. The system consists of a robot arm mounted on a vertical lift and a laser tracker, each on a portable base. The lift and laser tracker enable scanning a surface larger than the robot's reach. To accomplish this the robot first collects all points within its reach, then the system is moved and the laser tracker is used to relocate the robot before additional points are captured.The PLGR architecture will be discussed including how safety systems and path planning are combined to effectively characterize antennas. Software was written in high level languages for flexible integration of vector network analyzers and antenna controllers. Lastly, data will be shown to demonstrate the system functionality and accuracy.
As a potential replacement for stainless steel alloys commonly used to print parts with laser powder bed fusion, a new Cu precipitation strengthened ferrous alloy, with composition Fe-0.2C-6Cu (wt%), was recently developed. This material is Co- and Ni-free, printable, has mechanical properties comparable to that of high strength stainless steels (approximately 1300 MPa UTS), and is cost-advantaged relative to existing low-alloy steels for additive manufacturing of parts with complex shapes. To gain traction for broader application, optimal laser powder bed fusion (LPBF) processing conditions to produce nearly defect-free parts without compromising mechanical strength are needed. Here, an optimal processing window based upon laser speeds that achieve minimal porosity was quantified via comparisons of measured melt pool penetration, scan speeds, printed material density and laser beam energy density on a commercial LPBF unit operating at 350 W, 80 μm hatch spacing, and 50 μm layer thickness based upon optimal parameters for 17-4PH. Furthermore, the window is 300 to 500 mm/s to achieve >99.8 % dense Fe-0.2C-6Cu (wt%) specimens. Other defects such as burning, spatter, and lack of fusion were also avoided in this window. The window was validated with in-situ synchrotron X-ray imaging that enabled visualization of the vapor cavity, melting, and solidification during a single laser track scan on a miniature powder bed sample. In addition, in-situ infrared imaging provided temperature fields, cooling rate and solidification range, and confirmed minimal printing defects and spatter within the processing window.
This paper discusses an obstacle detection system applicable to a Mars Rover mission forseen possible in the early 1980's. The sensing device on the rover will be a laser rangefinder which scans the surface ahead of the vehicle. Terrain range data information is stored in matrix form. The range varies from point to point along the surface with sharp changes due to the presence of obstacles. The noise contaminated laser rangefinder readings are processed by an algorithm involving a modified version of the Kalman Filter, along with a decision scheme, to obtain complete outlines of discrete obstacles.
Carbon dioxide laser Doppler ground wind data were very favorably compared with data from standard anemometers. As a result of these measurements, two breadboard systems were developed for taking research data: a continuous wave velocimeter and a pulsed Doppler system. The scanning continuous wave laser Doppler velocimeter developed for detecting, tracking and measuring aircraft wake vortices was successfully tested at an airport where it located vortices to an accuracy of 3 meters at a range of 150 meters. The airborne pulsed laser Doppler system was developed to detect and measure clear air turbulence (CAT). This system was tested aboard an aircraft, but jet stream CAT was not encountered. However, low altitude turbulence in cumulus clouds near a mountain range was detected by the system and encountered by the aircraft at the predicted time.
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A laser Doppler velocimeter is described simultaneously measuring localized orthogonal velocity components in a fluid stream without perturbation of the flowfield. A first pair of beams of a first common wavelength and a second pair of beams of a second common wavelength are derived from a single laser source, directed along a single optical axis. The respective beams of each pair of beams are disposed parallel to the axis, symmetrically about the axis, and are positioned orthogonally about the axis relative to each other. The four beams are then focused upon a selected test volume within the flowfield. Light scattered at that point is collected by an appropriate optical system and focused onto photodetectors which develop electrical output signals commensurate with the orthogonal velocity components at the test point.
Moiré superlattices provide a highly tuneable and versatile platform to explore novel quantum phases and exotic excited states ranging from correlated insulators to moiré excitons. Scanning tunnelling microscopy has played a key role in probing microscopic behaviours of the moiré correlated ground states at the atomic scale. However, imaging of quantum excited states in moiré heterostructures remains an outstanding challenge. In this report we develop a photocurrent tunnelling microscopy technique that combines laser excitation and scanning tunnelling spectroscopy to directly visualize the electron and hole distribution within the photoexcited moiré exciton in twisted bilayer WS 2 . The tunnelling photocurrent alternates between positive and negative polarities at different locations within a single moiré unit cell. This alternating photocurrent originates from the in-plane charge transfer moiré exciton in twisted bilayer WS 2 , predicted by our GW-Bethe–Salpeter equation calculations, that emerges from the competition between the electron–hole Coulomb interaction and the moiré potential landscape. Our technique enables the exploration of photoexcited non-equilibrium moiré phenomena at the atomic scale.
Geometrical features and toolpath sequence are two important factors that cause process condition variations, such as variations in the meltpool temperature or meltpool size, that might lead to undesired material properties in the laser powder bed fusion (LPBF) process. Due to the high dynamics and complex physics of the LPBF process, it is difficult to predict variations in process conditions with simulations alone. Advances in measurement technology and computational technologies open up new possibilities for smart manufacturing. In this paper, a data-driven method to predict intra-layer variations in the processing conditions that source from the toolpath sequence and part geometry is presented. The approach is demonstrated using two-color on-axis pyrometer measurements. Three demonstration cases are presented in which it is demonstrated (1) how the trained predictive model can be used as a filter to ease the interpretation of process variations and discover patterns related to toolpath and part geometry, and (2) how to generate predictions that can be used for feedforward control, i.e., for adjusting laser power or scanning speed along the toolpath using a meltpool temperature prediction model generated based on on-axis measurements. Results show that the developed prediction model is able to meaningfully predict process variations resulted from toolpath sequence and geometry. Predictions are aligned with the results from the related work of others and for the case of 180° laser path turnarounds in our high-speed X-ray imaging experiments. In conclusion, the potential issues related to the current maturity status of the process and measuring equipment that could in practice affect the performance of the proposed solutions are also discussed.
This study systematically evaluates the effects of laser powder bed fusion additive manufacturing (L-PBF-AM) parameters (hatch spacing and laser power) on the thermomechanical behavior and microstructure of Ni 50.8 Ti 49.2 shape memory alloy. The samples were fabricated with hatch spacings from 40 to 240 µm and laser powers of 50 and 100 W at a constant scanning speed of 125 mm/s, resulting in parts with volumetric energy density levels from 55 to 666 J/mm 3 and two sets of linear energy densities of 0.4 and 0.8 J/mm. The results showed a reduced melt pool size and discontinuity of scan tracks with decreased laser power. Additionally, the porosity level was increased with larger hatch spacing and lower laser power. More notably, the transformation temperatures increased, and the critical stress, recoverable strain, and functional stability of samples improved with lower hatch spacing, where the recovery ratio of up to 90% was observed, regardless of the employed laser power. This study also discussed the relationship between the fabrication process and texture formation in the L-PBF-AM process. In conclusion, the advantage of L-PBF-AM was revealed in tailoring the microstructure from highly textured samples in [1 1 1] or [0 0 1] direction when hatch spacing lower than laser beam focused was employed, to the appearance of equiaxed solidification front with island grains and random orientations.