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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Collimated phase measuring deflectometry II: Re-design of the optical layout for high-curvature surfaces

Collimated phase measuring deflectometry (CPMD) is an optical metrology technique developed to improve upon traditional phase measuring deflectometry (PMD). CPMD utilizes telecentric imaging and collimated structured light illumination to eliminate the height-slope ambiguity present in traditional PMD measurements. After the publication of the first CPMD paper, efforts began to optimize the optical layout of the CPMD system. The first proposed change, and the one detailed in this work, was to move the Fourier transform (FT) lens closer to the surface under test (SUT). Moving the FT lens closer to the SUT meant that for a given FT lens diameter, a larger range of surface slopes on the SUT could be measured. This change to the optical layout was not trivial and introduced at least two concerns that had to be addressed: telecentricity in the imaging path and possible ghost reflections from the re-located FT lens. Here, in this work, we examine how these concerns were addressed and present results showing that the revised optical layout is capable of measurement results at least as good as the original CPMD optical layout. We also demonstrate the increased slope measuring range of the revised optical layout.

47 OTHER INSTRUMENTATION↗
NASA NTRS2006

Theodolite Ring Lights

Theodolite ring lights have been invented to ease a difficulty encountered in the well-established optical-metrology practice of using highly reflective spherical tooling balls as position references. A theodolite ring light produces a more easily visible reflection and eliminates the need for an autocollimating device. A theodolite ring light is a very bright light source that is well centered on the optical axis of the instrument. It can be fabricated, easily and inexpensively, for use on a theodolite or telescope of any diameter.

Clark, David↗
NASA NTRS2001

FIRST Mirror Review

As part of a JPL-funded effort to develop lightweight telescope technology suitable for far-infrared astronomy, COI designed and fabricated a spherical, f/1, 2-meter aperture prototype primary mirror using solely graphite/resin composite materials. To assess the performance of this technology, optical metrology of the mirror surface was performed from ambient to an intended operational temperature for IR-telescopes of 70K. Testing was performed horizontally in a cryogenic vacuum chamber at Arnold AFB, Tennessee. The test design had to accommodate requirements for rapid and uniform cooling across the optic, passivation of the ambient vibrational environment, and de-coupling of the mirror from the thermal strain of the test stand. An IR-wavelength phase shifting interferometer (PSI) was the primary instrument used to measure the mirror surface. From an initial surface figure of 2.1 microns RMS at ambient, a modest 3.9 microns of additional RMS surface error was induced at 70K. The thermally induced error was dominated by low-order deformations, of the type that could easily be corrected with secondary or tertiary optics. In addition to exceptional thermal stability, the mirror exhibited no measurable hysteresis between both ambient and cryo measurements.

Dodson, Kelly↗
DOE OSTI2025

Discorpy : algorithms and software for camera calibration and correction

Camera or lens-based detector calibration is essential for spatial accuracy in applications like dimensional tomography, optical metrology, and computer vision. Many methods and software exist yet there is still a lack of approaches that achieve both high accuracy and robustness while being easy to use and capable of handling a wide range of distortions. Radial lens distortion is common in high-resolution X-ray detector optics used in parallel-beam tomography at synchrotrons. Achieving sub-pixel accuracy requires calibrating with an optical target image. Although methods for characterizing radial distortion are well established, acquired images often also include perspective distortion and optical center offset. Here, we present our approaches to individually characterize and correct both types of distortion using a single calibration image, implemented in the Discorpy software.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Laser System for Precise, Unambiguous Range Measurements

The Modulation Sideband Technology for Absolute Range (MSTAR) architecture is the basis of design of a proposed laser-based heterodyne interferometer that could measure a range (distance) as great as 100 km with a precision and resolution of the order of 1 nm. Simple optical interferometers can measure changes in range with nanometer resolution, but cannot measure range itself because interference is subject to the well-known integer-multiple-of-2 -radians phase ambiguity, which amounts to a range ambiguity of the order of 1 m at typical laser wavelengths. Existing rangefinders have a resolution of the order of 10 m and are therefore unable to resolve the ambiguity. The proposed MSTAR architecture bridges the gap, enabling nanometer resolution with an ambiguity range that can be extended to arbitrarily large distances. The MSTAR architecture combines the principle of the heterodyne interferometer with the principle of extending the ambiguity range of an interferometer by using light of two wavelengths. The use of two wavelengths for this purpose is well established in optical metrology, radar, and sonar. However, unlike in traditional two-color laser interferometry, light of two wavelengths would not be generated by two lasers. Instead, multiple wavelengths would be generated as sidebands of phase modulation of the light from a single frequency- stabilized laser. The phase modulation would be effected by applying sinusoidal signals of suitable frequencies (typically tens of gigahertz) to high-speed electro-optical phase modulators. Intensity modulation can also be used

Dubovitsky, Serge↗
DOE OSTI2026

Phase-Dependent Squeezing in Dual-Comb Interferometry

Manipulating the quantum noise of continuous-wave lasers through squeezing has reshaped optical interferometry. However, progress in optical frequency comb interferometry with pulsed squeezed sources has been limited, despite the role of frequency combs in ultraprecise optical metrology. Here, we introduce a new time-domain approach to characterizing squeezed femtosecond light pulses using dual-comb interferometry. Time-domain interferograms are generated via multiheterodyne beating between the modes of a Kerr soliton-squeezed frequency comb and a coherent state comb. The interferogram noise reveals phase-dependent squeezing and antisqueezing, dipping as much as 3.8 ± 0.2 dB below the shot noise level at alternating zero crossings. We model this nonstationary quantum noise as a periodic optical displacement of the squeezed comb by the coherent comb. These results support a route toward quantum-enhanced dual-comb timing applications and high-speed quantum state tomography with dual-comb interferometers.

Herman, Daniel Issac [University of Colorado, Boul↗
NASA NTRS2011

Measuring the Cryogenic Optical Alignment Between the Telescope Element and the Instruments Module of the James Webb Space Telescope

The alignment between the Aft Optical Subsystem (AOS) and the Integrated Science Instruments Module (ISIM) is non-adjustable in orbit, so the alignment must be carefully verified in a cryogenic vacuum environment prior to launch. Optical point source locations calibrated by optical metrology instruments are imaged through the AOS onto the Science Instruments to determine focal, lateral, and clock angle alignment. The pupil image of the AOS is overlaid onto the pupil image of the NIRCam to determine the tip and tilt alignment. In addition, an image from fiducial lights at the Primary Mirror checks the pupil alignment between the telescope entrance pupil, the telescope pupil mask, and the NIRCam aperture stop. The image positions are combined to determine the relative alignment between the Optical Telescope Element (OTE) and the ISIM in all six degrees of freedom with corresponding alignment uncertainties. Uncertainties in the position of focused images of the test sources and images from the pupils are derived from sensitivities of an optical model of the system and the Science Instrument sensing capability. Additional uncertainty in the pupil alignment measurement is due to uncertainty in the analytical removal of gravity effects that simulate the on-orbit alignment environment.

Whitman, Tony↗
NASA NTRS2004

Theoferometer for High Accuracy Optical Alignment and Metrology

The accurate measurement of the orientation of optical parts and systems is a pressing problem for upcoming space missions, such as stellar interferometers, requiring the knowledge and maintenance of positions to the sub-arcsecond level. Theodolites, the devices commonly used to make these measurements, cannot provide the needed level of accuracy. This paper describes the design, construction, and testing of an interferometer system to fill the widening gap between future requirements and current capabilities. A Twyman-Green interferometer mounted on a 2 degree of freedom rotation stage is able to obtain sub-arcsecond, gravity-referenced tilt measurements of a sample alignment cube. Dubbed a 'theoferometer,' this device offers greater ease-of-use, accuracy, and repeatability than conventional methods, making it a suitable 21st-century replacement for the theodolite.

Toland, Ronald↗
DOE OSTI2026

Advancing extreme pulsed lasers through measurements: summary of the pulsed laser metrology workshop

In this report we present consensus findings produced during the pulsed laser metrology (PLM) workshop (Boulder, CO, USA, August 2025). The workshop was a meeting of 35 scientists from private industry, academia, and U.S. government to compile a list of the metrology needs to support extreme pulsed laser development and implementation. We define ‘extreme pulsed lasers’ loosely as those with peak powers above 1 TW or multi-Joule pulse energies. Such lasers are being increasingly used and investigated for use in high energy particle acceleration, short wavelength radiation generation, laser-based fusion, etc. The rapid growth of these fields and the proliferation of extreme lasers for these applications, coupled with the extreme electric fields they generate and relative scarcity of such lasers, presents unique challenges to accuracy in their measurement. The PLM workshop was a two-day event designed to hear from users, developers, and researchers on the current state of optical metrology associated with these extreme pulsed lasers. The goal was to identify the most important measurement challenges limiting development and implementation of these lasers in practical applications. We report here the conclusions and recommendations of this workshop. The hope is that this document will become the first of many iterations which track the status of measurement needs supporting extreme pulsed lasers.

Lasers↗
DOE OSTI2026

Future foundries: A convergent manufacturing platform

This article introduces the Future Foundries platform developed at Oak Ridge National Laboratory, a first-generation research system designed to demonstrate convergent manufacturing. Convergent manufacturing brings together additive, subtractive, and transformative processes in a digitally interconnected environment to enable end-to-end production workflows. By linking traditionally discrete steps, convergent platforms accelerate production, improve repeatability, and support high-mix, low-volume manufacturing. The Future Foundries platform exemplifies this vision in practice by combining four modular, vendor-agnostic process cells that include robotic WAAM, induction heating, optical metrology, and machining, coordinated through an automated pallet handler and a ROS 2-based digital thread. This architecture provides the flexibility and scalability needed for agile production in small and medium-sized manufacturing enterprises and for field deployable manufacturing. Two case studies illustrate the platform’s capabilities. The first presents an integrated workflow for fabricating, transforming, and repairing critical replacement components, showing how consolidated thermal, additive, inspection, and machining operations reduce manual part handling and streamline process flow. The second case study highlights coordinated multi-part production enabled by automated pallet logistics and multi-cell scheduling. Together, these examples showcase convergent manufacturing as a practical and scalable strategy for strengthening domestic casting and forging capacity, improving supply-chain resilience, and enabling rapid, adaptable production of mission-critical components.

Convergent manufacturing↗
DOE OSTI2024

Light scattering by V 4 O 7 film across the metal–insulator transition

The experimental study of the angle-resolved hemispherical light scattering by V 4 O 7 film within a broad temperature range across metal–insulator transition reveals complex structural reorganization of the film deposited on the c-cut sapphire crystal. The bidirectional scattering distribution function and the surface autocorrelation function were obtained from scattering data to visualize statistics of the spatially resolved contributions of optical inhomogeneities in normal and lateral directions to the surface. The measurements reveal an anisotropic surface roughness distribution due to the twinned domain structure, with significant anisotropy changes across the phase transition. The V 4 O 7 film deposited on sapphire leads to a polydomain structure, minimizing elastic strain energy with distinct multiscale distributions of surface domains. Near T c , the material shows the lowest roughness but the highest lateral disorder of the surface.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Spectral deconvolution without the deconvolution: Extracting temperature from x-ray Thomson scattering spectra without the source-and-instrument function

X-ray Thomson scattering (XRTS) probes the dynamic structure factor of the system, but the measured spectrum is broadened by the combined source-and-instrument function (SIF) of the setup. In order to extract properties such as temperature from an XRTS spectrum, the broadening by the SIF needs to be removed. Recent work [Dornheim et al. Nat. Commun. 13 , 7911 (2022)] has suggested that the SIF may be deconvolved using the two-sided Laplace transform. However, the extracted information can depend strongly on the shape of the input SIF, and the SIF is in practice challenging to measure accurately. Here, we propose an alternative approach: we demonstrate that considering ratios of Laplace-transformed XRTS spectra collected at different scattering angles is equivalent to performing the deconvolution, but without the need for explicit knowledge of the SIF. From these ratios, it is possible to directly extract the temperature from the scattering spectra, when the system is in thermal equilibrium. We find the method to be generally robust to spectral noise and physical differences between the spectrometers, and we explore situations in which the method breaks down. Furthermore, the fact that consistent temperatures can be extracted for systems in thermal equilibrium indicates that non-equilibrium effects could be identified by inconsistent temperatures of a few eV between the ratios of three or more scattering angles.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

FY2023 NSTTF Annual Report

The National Solar Thermal Test Facility (NSTTF) is a DOE Core Capability and Technology Deployment Center located in Albuquerque, NM. It is operated by Sandia National Laboratories (Sandia) for the U.S. Department of Energy (DOE). The NSTTF is the only multi-mission, multi-use, multi-story test facility of its type in the United States. The NSTTF was founded in 1978 and began testing with high heat flux that same year. Over the past 45 years, the NSTTF has been at the forefront of the research, design, fabrication, and testing of many of the critical Concentrating Solar Power (CSP) technologies. These technologies have allowed costs to be dramatically reduced from over $\$ $0.40 /kWh to $\$$0.12 /kWh since the conception of this renewable energy technology. The NSTTF has worked to make the Solar Energy Generating Systems (SEGS) parabolic trough plants successful, while also working with the Solar One and Solar Two facilities for successful implementation. Over the four decades since its founding, the mission of the NSTTF has grown to include new receiver technologies, like our generation 3 falling particle system (G3P3 Tower), optical metrology techniques like SOFAST, molten salt testing, thermal energy storage, solar thermal chemistry, and more. We continue to expand our capabilities in pursuit of the DOE SETO mission and the DOE SunShot 2030 goals: unsubsidized LCOE of $\$$0.05/kWh for CSP that includes 12 or more hours of thermal energy storage. To support both the DOE SETO mission and support the CSP sector as a whole, we are working to develop our operations and maintenance framework to provide a world class testing facility in support of our technological achievements. To accomplish both of these missions, the NSTTF draws on the decades of experience and expertise of our staff along with the world-class facilities at Sandia National Laboratories to further the science of concentrated solar thermal technologies in diverse applications. We remain a trusted partner for high-quality and impactful research in both fundamental and applied arenas. We are able to provide our partners with both one-of-a-kind testing platforms as well as world-class analytics.

14 SOLAR ENERGY↗
DOE OSTI2026

Roadmap to Advance Heliostat Technologies for High Temperature Solar-Thermal Systems

Since its establishment, the Heliostat Consortium (HelioCon) has made substantial progress toward closing many of the gaps in concentrating solar power (CSP) research. Numerous techno-economic studies have been performed, investigating topics ranging from the trade-off between size and temperature for industrial process heat applications to optimization of the heliostat design itself for various applications. Significant improvements have been made in optical metrology techniques, with first steps toward in situ measurement of heliostat fields. Several standards have been, and continue to be, developed with the coordination of an international group of CSP industry participants. Training programs have been developed, with universities including CSP in their engineering curricula, and many public webinars have been held to provide broad access to the latest CSP research. Improved CSP components such as mirror facets and wireless communication systems have been developed, and the solar tower at Sandia National Laboratories has been upgraded with a testbed for closed-loop controls research and development. Field deployment challenges involving heliostat foundations and sensitive wildlife habitats have been explored, with progress made toward methods for streamlining project development and permitting. Additional knowledge has been added to the body of work on wind behavior of heliostats and arrays of heliostats, with progress made toward a holistic understanding of wind design methods. Finally, techniques have been developed and demonstrated for assessing soiling conditions at a proposed project site, with predictive models for the soiling rate showing good results. Taking these results together, HelioCon has contributed greatly to the global CSP research and development effort over the past several years.

14 SOLAR ENERGY↗
NASA NTRS1979

Automated Plasma Spray (APS) process feasibility study: Plasma spray process development and evaluation

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal-barrier coatings to aircraft gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical blade positioner incorporating two interlaced six-degree-of-freedom assemblies; a noncoherent optical metrology subsystem; a microprocessor-based adaptive system controller; and commercial plasma spray equipment. Over fifty JT9D first stage turbine blades specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary specimens achieved an overall coating thickness uniformity of + or - 53 micrometers, much better than is achievable manually. Factors limiting this performance were identified and process modifications were initiated accordingly. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were initiated. One of the preliminary evaluation specimens was subjected to a torch test and metallographic evaluation.

Fetheroff, C. W.↗
NASA NTRS1981

Automated Plasma Spray (APS) process feasibility study

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal barrier coatings to aircraft and stationary gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical positioning subsystem incorporating two interlaced six degree of freedom assemblies (one for coating deposition and one for coating thickness monitoring); a noncoherent optical metrology subsystem (for in process gaging of the coating thickness buildup at specified points on the specimen); a microprocessor based adaptive system controller (to achieve the desired overall thickness profile on the specimen); and commerical plasma spray equipment. Over fifty JT9D first stage aircraft turbine blade specimens, ten W501B utility turbine blade specimens and dozens of cylindrical specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary turbine blade specimens achieved an overall coating thickness uniformity of 53 micrometers (2.1 mils), much better than is achievable manually. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were performed. One of the preliminary turbine blade evaluation specimens was subjected to a torch test and metallographic evaluation. Some cylindrical specimens coated with the APS process survived up to 2000 cycles in subsequent burner rig testing.

Fetheroff, C. W.↗
NASA NTRS1988

Development and applications of optical interferometric micrometrology in the angstrom and subangstrom range

The recent development of the scanning electron tunneling microscope and the atomic force microscope requires absolute standards for measurements in the angstrom and subangstrom range. Optical interferometry with lasers and multiple mode laser resonances can provide absolute measurements as the laser wavelengths are very accurately known. A key feature of such measurements is the use of piezoelectric crystals as translators of the highest accuracy for very small disturbances. However, the dimensional changes of these crystals resulting from electrical potential changes depend on many variables, among them the method of mounting, so that accurate calibrations are necessary. Starting from advances in optical metrology made by physicists trying to find gravity waves, advances which led to measurements down to 10 to the -5 A, the author designed and built a much simpler system for the angstrom range. The major limiting factors were mechanical vibrations, air currents, thermal changes and laser instabilities.

Lauer, James L.↗
NASA NTRS1989

Earth Science Geostationary Platform Technology

The objective of the workshop was to address problems in science and in four technology areas (large space antenna technology, microwave sensor technology, electromagnetics-phased array adaptive systems technology, and optical metrology technology) related to Earth Science Geostationary Platform missions.

Wright, Robert L.↗