Benchmarking solid-to-plasma transition modeling for inertial confinement fusion laser-imprint with a pump-probe experiment
Not Available
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
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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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Heat Treatment Optimization of Laser Powder Bed Fusion Additive Manufacture C103
Laser Powder Bed Fusion (L-PBF) and Laser Powder Directed Energy Deposition (LP-DED) additive manufacture C103 is in development for propulsion applications that operate under extreme environments. The standard post-process heat treatment has called for vacuum stress relief, however, depending on the application or certification requirements hot isostatic press (HIP) may be required. Although C103 density responds well to HIP the associated grain growth results in a reduction in mechanical properties. An investigation was conducted to look at the potential benefit of leveraging HIP followed by rapid cooling to minimize grain growth. A series of heat treatment schedules varying temperature and pressure were conducted followed by microstructural and mechanical characterization.
Additive Manufacturing↗
On the formation of swelling and related flaws in laser powder bed fusion
Process monitoring in laser powder bed fusion additive manufacturing can provide insights into stochastic anomalies, melt pool and plume dynamics, and part quality. Swelling, a build anomaly where overbuilt material protrudes through the powder layer after recoating, is readily detectable in post-recoat visible light images of the powder bed. Here, this work identifies several of the underlying mechanisms driving swelling formation by analyzing the influence of processing parameters, laser scan paths, and build plate locations on the presence of swelling detected in situ. Swelling near the edge of the part and swelling in the internal region of the part are shown to correlate with different process conditions. Edge and internal swelling may be driven by different phenomena, with edge swelling predominately occurring on the edge of a part facing the laser module and correlated to clusters of near-surface voids (detected with X-ray computed tomography). A larger spot size, higher laser power, and lower scan velocity also increased the presence of edge swelling. Laser spot size and scan path influenced internal swelling, which occurred preferentially with a larger spot size and in regions with large melt pools, caused by localized heat accumulation due to non-optimal processing parameters or scan path strategies. For coupons processed with a slicer-defined maximum scan vector length, swelling seldom occurred at internal vector-stripe boundaries. These results provide a mechanistic understanding of how swelling can be linked to material flaws, insight into how some instances of swelling can be avoided, and evidence supporting the use of swelling as an in situ indicator for quality assurance and part qualification.
Anomaly↗
Effects of spatial energy distribution-induced porosity on mechanical properties of laser powder bed fusion 316L stainless steel
Laser powder bed fusion (LPBF) additive manufacturing (AM) offers a variety of advantages over traditional manufacturing, however its usefulness for manufacturing of high-performance components is currently hampered by internal defects (porosity) created during the LPBF process that have an unknown impact on global mechanical performance. By inducing porosity distributions through variations in print energy density and inspecting the resulting tensile samples using computed tomography, nearly 50,000 pores across 75 samples were identified. Porosity characteristics were quantitatively extracted from inspection data and compared with mechanical properties to understand the strength of relationships between porosity and global tensile performance. Useful porosity characteristics were identified for prediction of part performance. Results indicate that ductility and strain at ultimate tensile strength are the global tensile properties most significantly impacted by porosity and can be predicted with reasonable accuracy using simple porosity shape descriptors such as volume, diameter, and surface area. Moreover, it was found that the largest pores influenced behavior most significantly. Specifically, pores in excess of 125 µm in diameter were found to be a sufficient threshold for property estimation. These results establish an initial understanding of the complex defect-performance relationship in AM 316L stainless steel and can be leveraged to develop certification standards and improve confidence in part quality and reliability for the broader set of engineering alloys.
36 MATERIALS SCIENCE↗
Inertial Electrostatic Confinement Fusion: The Laser Elevator Solar System Survey for Propellants Abstract
Dr. Wayne Pryor worked on three projects this summer. These were: 1) Inertial Electrostatic Confinement; 2) The Laser Elevator; and 3) Solar System Survey for Propellants Abstract. We Assisted Jon Nadler from Richland Community College in assembling and operating a table-top nuclear fusion reactor. We successfully demonstrated neutron production in a deuterium plasma. Pryor also obtained basic spectroscopic information on the atomic and molecular emissions in the plasma. The second project consisted of the completion of a paper on a novel propulsion concept (due to Tom Meyer of Colorado, the first author): a laser sail that bounces light back to the laser source. Recycling the photons from source to sail perhaps 100-1000 times dramatically improves the energy efficiency of this system, which may become very important for high-velocity missions in the future. Lastly, we compiled a very basic inventory of solar system propellant resources, their locations, and their accessibility. This initial inventory concentrates on sunlight availability, water availability, and the difficulty (delta-velocity requirement and radiation environment) in getting there.
Pryor, Wayne↗
Imaging the dynamics of initial laser-driven shocks and blowoff plasmas in polystyrene under laser-direct-drive fusion conditions
The dynamics of laser-driven shock propagation in solid ablator material, along with the concomitant processes of shinethrough and blowoff plasma plume expansion, at conditions relevant to laser-direct-drive fusion are measured using a tabletop system capable of supporting rapid dataset development with significantly higher resolution compared to existing methods. The experimental results are directly compared with current radiation-hydrodynamic simulations using the two-dimensional code . Discrepancies between experiments and simulations are evidenced and attributed to limitation of simulation to account for important processes involved in the solid-to-plasma transition. Published by the American Physical Society 2024
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
2025 Peregrine in-situ monitoring and training dataset for laser powder bed fusion and binder jet printers
Peregrine, a software tool developed at Oak Ridge National Laboratory (ORNL), was used to collect and analyze in-situ monitoring (ISM) data from a Concept Laser M2 (Colibrium Additive) laser powder bed fusion (L-PBF) printer and an ExOne Innovent (Desktop Metal) binder jet printer. Data for four builds (print jobs) were saved to HDF5 (high performance data) files for release. Additionally, process anomalies were annotated by the authors across 37 image stacks (i.e., print layers) and are also provided as HDF5 files.
36 MATERIALS SCIENCE↗
Experimental study of hot electron generation in shock ignition relevant high-intensity regime with large scale hot plasmas
In the shock ignition (SI) laser fusion scheme, hot electrons generated by the laser spike pulse can either preheat the fuel or strengthen the ignition shock, depending on the hot electron characteristics. We conducted a planar target experiment on the OMEGA-EP laser facility and characterized the temperature and total energy of hot electrons generated from a kilojoule-class 100-ps infrared (IR) or a 1-ns ultraviolet (UV) laser interacting with a large (L n ~330-450 μm) and hot (T e ~1-2 keV) coronal plasma at the SI-relevant intensities (~10 16 W/cm 2 ). The IR laser converts ~2.5% energy into hot electrons with T hot ~ 60–90 keV, while the UV laser couples 0.8% ± 0.7% energy into T hot =27 ± 9 keV hot electrons. The IR-produced hot electrons yield five times higher Cu Kα emission than the UV case, confirming the higher electron conversion efficiency with the IR laser. The low energy conversion from the UV laser to hot electrons may be due to the refraction of the off-normal incident laser in the large coronal plasma. These findings are the first comparisons of hot electron generation between the IR and UV pulses at kilojoule scales in SI-relevant large-scale plasmas. The findings may expand the SI design space to include IR lasers as the possible spike lasers.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Investigating the Potential and Limitations of Fast Scanning Calorimetry to Simulate the Laser Power Bed Fusion Coalescence Process
Laser-Based Powder Bed Fusion (PBF-LB) • PBF-LB is part of one of seven additive manufacturing techniques • Layer wise printing that selectively coalesces discrete powder particles into a solid object o Advantages: Low anisotropy, use of engineering grade materials o Weaknesses: lack of method standardization, challenges in controlled post print quality
Blackman, Malik A. [Georgia Inst. of Technology, A↗
Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective
Abstract 316L stainless steel (316L SS) is a flagship material for structural applications in corrosive environments, having been extensively studied for decades for its favorable balance between mechanical and corrosion properties. More recently, 316L SS has also proven to have excellent printability when parts are produced with additive manufacturing techniques, notably laser powder bed fusion (LPBF). Because of the harsh thermo-mechanical cycles experienced during rapid solidification and cooling, LPBF processing tends to generate unique microstructures. Strong heterogeneities can be found inside grains, including trapped elements, nano-inclusions, and a high density of dislocations that form the so-called cellular structure. Interestingly, LPBF 316L SS not only exhibits better mechanical properties than its conventionally processed counterpart, but it also usually offers much higher resistance to pitting in chloride solutions. Unfortunately, the complexity of the LPBF microstructures, in addition to process-induced defects, such as porosity and surface roughness, have slowed progress toward linking specific microstructural features to corrosion susceptibility and complicated the development of calibrated simulations of pitting phenomena. The first part of this article is dedicated to an in-depth review of the microstructures found in LPBF 316L SS and their potential effects on the corrosion properties, with an emphasis on pitting resistance. The second part offers a perspective of some relevant modeling techniques available to simulate the corrosion of LPBF 316L SS, including current challenges that should be overcome.
Voisin, T. (ORCID:0000000287462659)↗
Laser-enhanced fusion burn fractions for advanced fuels
Not Available
Bekx, John Jasper (ORCID:0000000259105742)↗
Kinetic Model Evaluation of the Resilience of Plasmonic Nanoantennas for Laser-Induced Fusion
Not Available
Papp, István↗
Melt Pool Boundaries and the Corrosion of Laser Powder Fusion Stainless Steels.
Abstract not provided.
Melia, Michael Anthony↗
Gas Optics for Inertial Fusion Energy Lasers
Explore the source record for details and available documents.
Lasers↗
Time-gated measurements of fusion-class laser beam profiles
Explore the source record for details and available documents.
Lasers↗
The influence of laser power modulation on melt pool dynamics in laser powder bed fusion
While the majority of laser powder bed fusion (LPBF) metal additive manufacturing uses a continuous wave (CW) laser heat source, some commercial applications of LPBF additive manufacturing instead involve the modulation of the laser power on tens-of-microsecond timescales as an adjustable process variable. This article reports the use of in situ, high speed x-ray and optical imaging to probe melt pool fluid flow, defect formation, and nearby powder motion during LPBF with both modulated and CW laser heat sources. We observe melt pool dynamics unique to modulated laser melting even at very high duty cycles that are related to fluctuations in vapor depression depth, complex pore formation mechanisms, and changes to denudation physics when compared to CW melting. These behaviors are present in Ti–6Al–4V, 316L stainless steel, and AL1100 alloys but vary slightly as a function of material, indicating a substantial dependence on the viscosity and surface tension of the liquid metal. While high duty cycles produce weld tracks of comparable quality to CW melting, lower duty cycles introduce substantial defect concentrations. At intermediate duty cycles, careful control of modulation parameters can repeatably and precisely yield one pore per laser pulse, suggesting a method for intentionally inserting engineered porosity at specific sites during an LPBF build.
3D printing↗
Optimization of stochastic feature properties in laser powder bed fusion
Process parameter selection in laser powder bed fusion (LPBF) controls the as-printed dimensional tolerances, pore formation, surface quality and microstructure of printed metallic structures. Measuring the stochastic mechanical performance for a wide range of process parameters is cumbersome both in time and cost. As such, in this study, we overcome these hurdles by using high-throughput tensile (HTT) testing of over 250 dogbone samples to examine process-driven performance of strut-like small features, ~1 mm 2 in austenitic stainless steel (316 L). The output mechanical properties, porosity, surface roughness and dimensional accuracy were mapped across the printable range of laser powers and scan speeds using a continuous wave laser LPBF machine. Tradeoffs between ductility and strength are shown across the process space and their implications are discussed. While volumetric energy density deposited onto a substrate to create a melt-pool can be a useful metric for determining bulk properties, it was not found to directly correlate with output small feature performance.
316 L stainless steel↗
In situ study on radiation response of tungsten manufactured by laser powder bed fusion
Tungsten (W) produced by laser powder bed fusion (LPBF) was examined by in situ Krypton (Kr) ion irradiation at 400 °C up to 2.52 displacements per atom (dpa) to investigate its radiation response. Dislocation loops with identical Burgers vectors form aligned raft structures, inducing significant grain misorientation accumulation. Defect saturation was observed beyond 0.36 dpa, marked by constant loop density and raft spacing. WO 3 nanoparticles are found in the as-printed matrix and served as efficient defect sinks. Dislocation loops were absorbed at the W/WO 3 interface, facilitating defect annihilation and suppressing defect accumulation. In conclusion, these findings highlight the role of LPBF microstructure and oxide interfaces in mediating radiation-induced defect evolution, offering insights for designing radiation tolerant W-based materials.
Defect sink↗