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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
NASA NTRS1979

Laser measuring system for wire-wrapped frame assemblies

The laser measuring system is designed to automatically measure and record the distances between small diameter wires on a wire wrapped grid frame assembly to an accuracy of 0.00635 mm (0.00025 in.). The system utilizes a helium-neon gas laser beam as the measuring instrument with a remote interferometer and retroreflector, a light source and photodetector to detect the wire positions, in conjunction with recording, display and printout units. The laser measuring system is utilized to perform precise automatic measurements for wire application machines or as an automatic feedback device for positioning wires and/or to adjust them for out of tolerance conditions.

Etzel, J. G.↗
NASA NTRS1982

Comparison of hot wire/laser velocimeter turbulence intensity measurements

The question of whether a random measure of particle velocities yields a good statistical estimate of the stationary condition of the turbulence flow field was investigated by comparing hot-wire and laser velocimeter turbulence intensity measurements. Great care was taken to insure that the instrument precision of both the laser velocimeter and hot wire was maximized. In this attempt to reduce the measurement uncertainties in the hot wire, direct digitization of the analog output signal was performed with point-by-point conversion to velocity through a spline fit calibration curve and the turbulence intensity function was calculated statistically. Frequent calibrations of the hot wire were performed using the laser velocimeter as the velocity standard to account for the presence of the small seed particles in the air flow and signal drift in the hot wire.

Meyers, J. F.↗
DOE OSTI2023

Hybrid Al Casting + AM Components for Automotive Applications

Although casting Aluminum (Al) alloys is widely used for automotive application, the conventional casting process is showing limitations for modern vehicle production. A hybrid manufacturing method that is capable of fabricating automotive structures with tailored functionality and tuned attributes at a high production rate is proposed in this project, utilizing the merits of conventional casting methods and additive manufacturing (AM) methods. Ford is interested in supplementing conventional casting processes (e.g., shape casting, high pressure die casting) with local modifications to geometry and microstructure using additive manufacturing techniques. Two additive manufacturing methods, wire-arc and laser hot-wire directed energy deposition AM process, were evaluated by deposition of 4043 filler wire onto high-pressure die cast and permanent mold cast Al-Si alloys. The feasibility of this hybrid manufacturing method was determined through trial deposition and evaluation of defects, microstructure, and mechanical properties. Laser hot-wire deposition was found to be beneficial for this application with low porosity, a refined microstructure, and mechanical properties similar to those reported in the literature for 4043. The mechanical properties of the interface between the A356 casting and deposited 4043 were found to be controlled by the weaker deposit material.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A multi-institution collaboration to study copper wire hybrid and laser-cut foil X-pinches

X-pinches are a pulsed power wire-array configuration that produce nanosecond and micron-scale X-ray sources with numerous applications. The earliest embodiment of the X-pinch inspired its name, as it is typically composed of two or more fine (5-50 µm) wires crossed into the shape of an X (Fig. 1a). The ‘X’ ablates when subjected to large (10 1 -10 4 kA), fast-rising (~1 kA/ns) currents, and extreme magnetic pressure at the cross-point constricts the ablated plasma, which develops instabilities and then pinches to near-zero radius, localized ‘hot spots’, emitting X-rays from a sub-nanosecond and 1 µm scale source characteristic of a hot (~1 keV), dense (10% solid density) plasma. A subsequent gap forms where the hot spot(s) occurred, across which substantial potential accelerates electron beams (e-beams) that generate larger, longer-lasting X-ray bursts composed of harder X-rays.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS1982

A comparison of turbulence intensity measurements using a laser velocimeter and a hot wire in a low speed jet flow

The study involves a simultaneous measurement with both instruments along radial scans at two axial locations in the jet exiting from the turbulent pipe and an axial scan at the 75-percent radial location in the jet from the convergent nozzle. The results suggest that, within the limits of flow stationarity, both instruments yield measurements in good agreement, + or - 0.8-percent in turbulence intensity, below a turbulence intensity (the ensemble standard deviation divided by the local mean velocity) of 20 percent. From turbulence intensities of 20 percent to a maximum of 75 percent, the measurements exhibit the same trends; for reasons discussed here, however, the comparisons are not of the quality as those below 20 percent. It is found that correcting the turbulence intensity data for velocity bias errors increases the results by an average of 2 percent in turbulence intensity above the hot wire results and the uncorrected laser velocimeter data. The results are seen as calling into question the validity of using the velocity bias correction and time average techniques for turbulence intensity measurements.

Meyers, J. F.↗
NASA NTRS1990

Turbulence and shear stress measurements in hypersonic flow

An assessment has been made of the potential for hot wire and laser anemometer measurements of turbulent fluctuations in hypersonic flow fields. The results of laser velocimeter experiments conducted in two hypersonic wind tunnels are reported and comparisons made with previous hot wire turbulence measurements. A new concept for the measurement of the compressible shear stress terms which combines the attributes of both hot wire and laser anemometry is presented.

Owen, F. K.↗
NASA NTRS1994

Excimer laser produced plasmas in copper wire targets and water droplets

Elastically scattered incident radiation (ESIR) from a copper wire target illuminated by a KrF laser pulse at lambda = 248 nm shows a dinstinct two-peak structure which is dependent on the incident energy. The time required to reach the critical electron density (n(sub c) approximately = 1.8 x 10(exp 22) electrons/cu cm) is estimated at 11 ns based on experimental results. Detailed ESIR characteristics for water have been reported previously by the authors. Initiation of the broadband emission for copper plasma begins at 6.5 +/- 1.45 ns after the arrival of the laser pulse. However, the broadband emission occurs at 11 +/- 0.36 ns for water. For a diatomic substance such as water, the electron energy rapidly dissipates due to dissociation of water molecules, which is absent in a monatomic species such as copper. When the energy falls below the excitation energy of the lowest electron state for water, it becomes a subexcitation electron. Lifetimes of the subexcited electrons to the vibrational states are estimated to be of the order of 10(exp -9) s. In addition, the ionization potential of copper (440-530 nm) is approximately 6 eV, which is about two times smaller than the 13 eV ionization potential reported for water. The higher ionization potential contributes to the longer observed delay time for plasma formation in water. After initiation, a longer time is required for copper plasma to reach its peak value. This time delay in reaching the maximum intensity is attributed to the energy loss during the interband transition in copper.

Song, Kyo-Dong↗
NASA NTRS1994

Propagation velocities of laser-produced plasmas from copper wire targets and water droplets

Experiments were performed to determine the plasma propagation velocities resulting from KrF laser irradiation of copper wire target (75 microns diameter) and water droplets (75 microns diameter) at irradiance levels ranging from 25 to 150 GW/sq cm. Plasma propagation velocities were measured using a streak camera system oriented orthogonally to the high-energy laser propagation axis. Plasma velocities were studied as a function of position in the focused beam. Results show that both the shape of the plasma formation and material removal from the copper wire are different and depend on whether the targets are focused or slightly defocused (approximately = 0.5 mm movement in the beam axis). Plasma formation and its position relative to the target is an important factor in determining the practical focal point during high-energy laser interaction with materials. At irradiance of 100 GW/sq cm, the air plasma has two weak-velocity components which propagate toward and away from the incident laser while a strong-velocity component propagates away from the laser beam as a detonation wave. Comparison of the measured breakdown velocities (in the range of 2.22-2.27 x 10(exp 5) m/s) for air and the value calculated by the nonlinear breakdown wave theory at irradiance of 100 GW/sq cm showed a quantitative agreement within approximately 50% while the linear theory and Gaussian pulse theory failed. The detonation wave velocities of plasma generated from water droplets and copper wire targets for different focused cases were measured and analyzed theoretically. The propagation velocities of laser-induced plasma liquid droplets obtained by previous research are compared with current work.

Song, Kyo-Dong↗
DOE OSTI2025

Increased electron, positron, and x-ray production from high intensity laser interactions using micro-wire targets

We report increases in energetic electrons, positrons, and x-rays emitted from high-intensity laser interactions (10 18−20 W/cm 2 ) with structured silicon micro-wires on the surface of a 1 mm gold converter target using a 10 ps laser pulse. A total of four different wire configurations are tested, where the gaps (7–28 μm) between the wires and the thicknesses (3–6 μm) of the wires are varied, while the height remains constant (⁠ ~25 μm). We observe the largest enhancement in electrons, positrons, and x-rays with the sparsest wire configurations. The electron temperature (T e ≈6 MeV) remains consistent across all shots, regardless of whether wires or planar targets are used. This suggests that the observed enhancement is due to increased laser light absorption by the accelerated electrons over a long scale length. Two-dimensional particle-in-cell simulations confirm that absorption is significantly enhanced with the wire target. Additionally, specific simulations examining laser pointing on different parts of the wire structure reveal that, while the final electron spectrum remains largely insensitive, the angular distribution is highly sensitive to these variations.

Bremsstrahlung↗
DOE OSTI2022

Wire, hybrid, and laser-cut X-pinches as Talbot–Lau backlighters for electron density diagnostics

Talbot–Lau x-ray deflectometry (TXD) enables refraction-based imaging for high-energy-density physics experiments, and thus, it has been studied and developed with the goal of diagnosing plasmas relevant to inertial confinement and magnetic liner inertial fusion. X-pinches, known for reliably generating fast (~1 ns), small (~1 µm) x-ray sources, were driven on the compact current driver generator for ablation structure and implosion studies (~200 kA, 150 ns) as a potential backlighter source for TXD. Considering that different X-pinch configurations have characteristic advantages and drawbacks as x-ray generating loads, three distinct copper X-pinch configurations were studied: the wire X-pinch, the hybrid X-pinch, and the laser-cut X-pinch. Furthermore, the Cu K-shell emission from each configuration was characterized and analyzed regarding the specific backlighter requirements for an 8 keV TXD system: spatial and temporal resolution, number of sources, time of emission, spectrum, and reproducibility. Recommendations for future experimental improvements and applications are presented. The electron density of static objects was retrieved from Moiré images obtained through TXD. This allowed to calculate the mass density of static samples within 4% of the expected value for laser-cut X-pinches, which were found to be the optimal X-pinch configuration for TXD due to their high reproducibility, small source size (≤5 µm), short duration (~1 ns), and up to 106 W peak power near 8 keV photon energy. Plasma loads were imaged through TXD for the first-time using laser-cut X-pinch backlighting. Experimental images were compared with simulations from the x-ray wave-front propagation code, demonstrating that TXD can be a powerful x-ray refraction-based diagnostic for dense Z-pinch loads. Future plans for Talbot–Lau interferometry diagnostics in the pulsed-power environment are described.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Initial Process Planning of a Hybrid Multi-Tasking Platform

Abstract Applications of hybrid technology are expanding from refurbishment and repair to low quantity, specialty part production, which are staple characteristics in medical implant, energy, and aerospace industry sectors, among others. This expansion has led to the development of the Mazak VC-500A/5X AM HWD, a wire fed laser cladding unit equipped with a standard 5 axis CNC. This unit is capable of building near net geometry of complex medium to large parts within a profitable timeframe, due to its comparatively high rate of deposition to that of a powder fed hybrid system. In this study, deposition and machining capabilities of the VC-500A/5X AM HWD are assessed through the production of three different test geometries by different process plans. Production of these test geometries is supported by an open loop sensor package primarily for monitoring machine health, data collection, and machine operator aid. The viability of extended deposition followed by machining is evaluated against a more cyclical strategy of reoccurring deposition and machining operations. Lastly, common defects in as-built geometries are evaluated and addressed through revisions to original process plans and toolpaths, indicating the need for continued innovation in hybrid manufacturing specific CAM/CAD software, as well as closed loop machine monitoring and quality control.

DeWitte, Lisa N.↗
DOE OSTI2022

On the Prediction of Uniaxial Tensile Behavior Beyond the Yield Point of Wrought and Additively Manufactured Ti-6Al-4V

In this paper, phenomenological relationships are presented that permit the prediction of the plastic regime of stress–strain curves using a limited number of parameters. These relationships were obtained from both conventional (wrought + β annealed) and additively manufactured (i.e., “3D printed”) Ti-6Al-4V. Three different methods of additive manufacturing have been exploited to produce the materials, including large-volume electron beam additive manufacturing, large-volume laser hot wire additive manufacturing, and small-volume selective laser melting. The general fundamental expressions are independent not only of the additive manufacturing process, but also of a wide variety of post-deposition heat treatments, however the coefficients are specific to material states. Thus, this work demonstrates that it is possible to predict not only the ultimate tensile strength, but also the full true stress, true strain curves, if certain parameters of the material are known. In general, the prediction of ultimate tensile strength are within 5% of the experimentally measured values across all additive manufacturing variants and subsequent heat treatments. The absolute values of ultimate tensile strength range from ~ 910 MPa to ~ 1170 MPa for the single alloy Ti-6Al-4V. Data representing 113 explicit samples are included in this work.

36 MATERIALS SCIENCE↗
DOE OSTI2025

THz Radiation Generation to Enable Internal Magnetic Field Measurement of Burning Plasmas (Final Scientific Report)

A one-year experimental program was performed using the Multi-TeraWatt (MTW) laser at the Laboratory for Laser Energetics (LLE) to investigate the efficiency and physical process of laser-driven—wire THz generation. This process was evaluated as a potential high-repetition-rate source of powerful THz pulses for use in THz pulsed polarimetry of a moderate-density magnetic-confinement fusion concept developed by TAE. The goal was to develop a source for short pulses in the THz regime (150 μm wavelength) containing 10’s of mJ. The campaign tested the impact of Cu wire diameter (25, 75, 160 μm), length (250 – 750 μm), and laser irradiation orientation on THz production efficiency in comparison to 20-μm thick Cu foils. Of these targets, the 160 µm diameter, 750 µm long wires with sharpened tips and irradiated at the base were found to produce the highest energy and shortest wavelength THz pulses, exceeding 2.5 Joule/sr and meeting the requirements for the polarimetry diagnostic. The brightest THz signal was radiated in the direction of the sharpened wire tip. A combination of two models – a traveling wave antenna combined with coherent transition radiation – describes the emission pattern, pulse energy, and spectrum observed in the experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRSDate not supplied

AM Processes Part 2: Principles of Directed Energy Deposition

Directed Energy Deposition (DED) is one of the metal additive manufacturing processes which finds wider industrial applications, particularly for repair and reclamation, and for large structures. This course helps the attendees to understand the fundamental concepts of DED process and covers the topics such as, how the technology works, different DED processes, materials used, and typical applications where this technology is used. The discussion will have a focus on ASTM F3187 – Standard guide for Directed Energy Deposition of Metals. After completing this webinar the attendees will achieve the following: · Identify and understand the different types of DED processes · Understand how to select a DED process and trade criteria · Understand the various materials used for DED processes · Understand the core parameters for the DED processes · Determine potential parts and end application of DED technology

Additive Manufacturing↗
NASA NTRS1976

Turbulence measurements in a transonic boundary layer and free-shear flow using laser velocimetry and hot-wire anemometry techniques

Quantitative measurements of the turbulence fluctuations in velocity and mass flux have been obtained in Mach 0.6 and 0.8 turbulent boundary layer and free-shear layer flows by laser velocimetry and hot-wire anemometry techniques. To evaluate the effects of compressibility, these transonic data are compared to available incompressible and supersonic results. Based on some simplifying assumptions, estimates of the rms density fluctuations are made for which error bounds are given. In addition to these fluctuation data, the compressible mean velocity data obtained with the laser velocimeter are presented and compared to pitot tube results. The investigation was conducted in the Ames 6- by 6-Foot Supersonic Wind Tunnel at free-stream Mach numbers of 0.6 and 0.8 for a unit Reynolds number of about 10,000,000 per meter.

Johnson, D. A.↗