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DOE OSTI2025

In situ Visible Light and Thermal Imaging Data from a Laser Powder Bed Fusion Additive Manufacturing Process Co-Registered to X-ray Computed Tomography and Fatigue Data

This dataset is comprised of in situ sensing data collected during a laser-based powder bed fusion additive manufacturing process, as well as rasterized scan path information, post-build X-ray computed tomography (XCT), and fatigue test results. A total of 64 cylinders, approximately 15 mm in diameter and 102 mm tall, were printed out of stainless steel 316H on a Colibrium Additive Concept Laser M2 Series 5 machine. Parameters known to produce dense material were used to construct 56 of these cylinders, while the remaining 8 cylinders were printed with relatively high energy density parameters prone to producing keyhole pores. In addition, two spatter generation blocks were constructed upstream of the 64 cylinders such that ejecta produced during the melting of the spatter generators were stochastically seeded onto the 64 cylinders. Based on previous experiments, these spatter particles were theorized to produce stochastic lack-of-fusion pores. During the construction of the build, high-resolution images of reflected light in the visible spectrum were captured both before and after recoating for each print layer. Additionally, temporally integrated thermal imaging in the near infrared spectrum produced integrated sum and max images on a layerwise basis. The multimodal in situ data has been co-registered to the build plate coordinate system, allowing for identification of process anomalies (e.g., spatter particles) apparent in the two sensors. Following construction of the build, the cylinders were subjected to XCT to identify internal flaws, and the resulting data have also been registered to the build plate coordinate system. Finally, 60 of the 64 cylinders were machined into fatigue coupons conforming to ASTM E466 and subsequently subjected to either high- or -low-cycle fatigue testing. The results of the fatigue tests have also been included in the dataset, and the XCT data corresponded to the approximate location of the gauge sections of the machine fatigue specimen geometry.

42 ENGINEERING↗

DOE OSTI2026

Design of a broadband, high-power, off-axis spiral polarization reflector

Spirally polarized beams are known to produce a strong longitudinal field under high numerical aperture focusing. Here, we report on the design of a reflective optical element with an off-axis geometry that is capable of transforming a uniformly polarized beam into a predominantly spirally polarized beam. By utilizing the retardance present in Fresnel reflection, our device can operate over a broad range of wavelengths. The output polarization and intensity structure of a beam passing through the reflector are calculated using polarization and scalar ray tracing. Vector diffraction is used to calculate the polarization and intensity structure under $f/0.656$ focusing. The off-axis reflective design is well-suited for high-power laser applications and could enable current and future laser-based particle accelerators to achieve strong longitudinal fields at focus.

Black, A. Nicholas [Univ. of Rochester, NY (United↗

DOE OSTI2025

Investigation of a gallium alloy liquid metal mirror for application in inertial fusion energy systems

The final optic in future inertial fusion energy plants must maintain high performance and survivability under gigashot laser irradiation while exposed to fusion byproducts. Although no practical solution has been demonstrated, a self-healing final turning mirror based on a grazing-incidence liquid metal mirror has been theoretically explored. This work investigates the suitability of a gallium alloy. The experimental system simulates key conditions, including vacuum exposure and 10-Hz, 355-nm, and 6-ns laser pulses. Experiments address reflectivity, damage, and response as a function of pressure. Results highlight the potential of liquid metal gallium alloys for robust final optics in laser-based fusion power plants and inform non-traditional optics for intense laser systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Redefining precision interferometry and spectroscopy with high-performance optical interference coatings

High-performance optical interference coatings have transformed precision interferometry and spectroscopy by enabling unparalleled control over light–matter interactions. This review explores recent innovations in ion-beam sputtered amorphous dielectric, as well as substrate-transferred crystalline coatings, and their impact on systems at the forefront of precision metrology. These state-of-the-art coating techniques generate multilayers with ultralow optical losses, yielding mirrors with exceptional reflectivity. Refinements in their noise performance push the ultimate limits of sensitivity, resolution, and stability in demanding laser-based metrology applications. These technologies underpin the most advanced timekeeping and spatial measurement tools, enabling high-finesse reference cavities for the world’s most precise optical atomic clocks and low-noise reflective test masses for km-baseline gravitational-wave detectors. Emerging hybrid designs combining these techniques expand access to the mid-infrared spectral region, enabling the first ultralow-optical-loss coatings in the 3000–5000 nm wavelength range for enhanced spectroscopy and trace-gas detection. We highlight how these technologies redefine coating performance metrics and set new benchmarks in quantum science, fundamental physics, and precision optical sensing.

Cole, Garrett D. [University of Arizona, Tucson, A↗

DOE OSTI2026

Towards robust laser beam propagation in atmospheric turbulence

High-fidelity optical propagation through the atmosphere is essential for free-space optical technologies, including laser-based remote sensing and optical communication. However, atmospheric turbulence severely distorts beams and compromises system performance. In this work, we employ hypergeometric-Gaussian (HyGG) vortex beams as probes to characterize and mitigate atmospheric turbulence. Using over 250,000 experimental and simulated frames, we show that refining the power spectrum density (PSD) can reduce numerical prediction errors by up to 79.8%. Concurrently, experimental observations supported by numerical simulations demonstrate that HyGG beams exhibit superior turbulence resilience across multiple metrics compared to conventional Gaussian beams, particularly in their ability to withstand over 5 times stronger turbulence while maintaining similar intensity fluctuations. These dual investigations, on both turbulence mitigation and robust beam solutions, converge to form a unified strategy for enhancing free-space optical system performance. Collectively, our findings provide new insights into light–turbulence interactions and highlight the practical utility of vortex beams under atmospheric conditions.

Zhang, Boyu↗

DOE OSTI2025

A review of laser materials processing paradigms

Laser-based processing of materials has progressed from traditional applications such as macroscale cutting and welding, to sophisticated techniques, including ultrafast micromachining, additive manufacturing, and surface engineering at micro- and nano-metric scales. Innovations in laser source technology, particularly the advent of high-power and ultrashort-pulse lasers, have expanded the range of processable materials, enabled a plethora of manufacturing applications, and propelled groundbreaking research in optics, photonics, electronics, and biomedical domains. In this article, we provide a concise, yet broad review of the congruent evolution of lasers and materials processing, and highlight seminal developments in the field over the years, combined with a critical assessment of the state of the art. Finally, we also provide an outlook on emerging needs, as well as a roadmap of anticipated developments in laser technologies and materials platforms over the next 50 years.

Lasers↗

DOE OSTI2025

Experimental investigation of longitudinal scraping of H- bunches via photo-detachment

Longitudinal emittance growth is a significant challenge in RF linacs, especially for poorly bunched beams. This stems from particles occupying outer synchrotron oscillation orbits in the LBET, causing unwanted bunch-bunch interactions and degraded beam quality. To address this, we proposed using temporally spaced laser pulses to selectively photo-detach electrons from the longitudinal head and tail regions of H- ion bunches. This approach aims to reduce particle density in extreme orbits, enhancing beam uniformity and limiting emittance growth. Our experiments employed Fermilab's 'LaserNotcher' system at the font end of the linac, delivering 1.6 MW peak power with sub-nanosecond precision. By neutralizing the first and last half-nanosecond of several H- bunches, we measured their propagation injection into the booster. Measurements of pulse width, average height, and temporal spacing over booster cycles were compared between the scraped and unscraped bunches. Statistical analysis evaluated the results’ significance, highlighting the feasibility of laser-based scraping for future linac designs to achieve higher beam energies with improved emittance control.

Landon, Parker [Boston U.]↗

DOE OSTI2024

Topological Excitations in Pyrochlore Heterostructures

This research project focuses on developing innovative materials that demonstrate unique quantum properties, specifically within electron systems that exhibit complex interactions, known as "correlated electron systems." Unlike non-correlated materials, finding topological phases (special states of matter with protected properties that make them stable against defects) in these correlated systems is a significant challenge. The project aims to design synthetic templates of two-dimensional "Kagome lattice" structures, made from specific materials called iridates and osmates, to study and control these exotic quantum behaviors. To achieve this, the project employs a cutting-edge spectroscopic tools that allow precise analysis of artificial quantum materials in terms of both energy and momentum while they are being created, using a specialized laser-based process called laser Molecular Beam Epitaxy.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Electronics Free Laser Sensing Technology for Minerals and Technology Elements

This presentation presents an electronics free laser sensing technique and its ongoing and potential applications. A laser-based technique, popularly known as laser-induced breakdown spectroscopy has been prototyped for the determination of high-tech elements including rare earth elements and other elements in solid as well as aqueous sources. All optical unit without any electronics has been designed in such a way that it can be installed in the source environment and connected to other required components for controlling and data acquisition from the workstation. Measurement methods and results obtained for selected elemental species and overall performance of the developed prototype will be presented.

HCM Sensor↗

DOE OSTI2025

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↗

DOE OSTI2025

Experimental investigation of longitudinal scraping of $H-$ bunches via photo-detachment

Landon, P. [Boston U.; Fermilab]↗

DOE OSTI2025

Dual-Comb Spectroscopy to Tethered Balloon System (DCS to TBS) Field Campaign Report

There is a critical need for the ability to detect, quantify, and attribute sources and sinks of greenhouse gases (GHGs) with high temporal and spatial resolution. Current methods are typically based on continuously operating near-surface point sensors or intermittent aerial/satellite observations. Dual optical frequency comb spectroscopy (“dual-comb spectroscopy”; DCS) is a laser-based technique that can bridge this sensing gap by providing high-precision, high-accuracy, and high-temporal-resolution detection and quantification of trace gases over kilometer-length scales, connecting local and regional observations. A single DCS system can also provide spatial resolution for source/sink attribution with the addition of a few minor optical elements, enabling cross-validation of other observations (e.g., Total Carbon Column Observing Network [TCCON], Orbiting Carbon Observatory [OCO-2/3], Greenhouse Gases Observing Satellite [GOSAT-1/2][).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

High-Efficiency Recycled Silicon Solar Cell

The project, High-Efficiency Recycled Silicon Solar Cell, addresses the critical challenge of end-of-life (EoL) photovoltaic (PV) waste, which is expected to reach 78 million tons by 2050. Traditional recycling methods for recovering valuable materials like silver from silicon solar cells are inefficient, environmentally harmful, and economically unfeasible. Therefore, presently waste solar cells end up as landfills. This project aimed to develop a green, scalable, laser-based method for silver recovery, avoiding hazardous chemicals and minimizing operational costs. This research contributes to the circular economy in the renewable energy sector by enhancing material recovery from PV waste.

14 SOLAR ENERGY↗

DOE OSTI2024

Microstructure Optimization and Novel Processing Development of ODS Steels for Fusion Environments (Final ARPA-E Report)

This project aimed to develop scalable, cost-effective fabrication of high-performance, oxide- dispersion-strengthened (ODS) steel using advanced manufacturing methods (AMMs) for fusion blanket-breeding applications. Gas atomization reaction synthesis (GARS) enables the synthesis of precursor ODS steel powders without prolonged mechanical alloying. This process creates a chromium (Cr)-enriched surface oxide with yttrium/titanium (Y/Ti)-enriched intermetallics in powder interiors. GARS powders were consolidated to >99% of the theoretical density using a first-of-a-kind shear assisted processing and extrusion (ShAPE) and laser-based powder bed fusion (L-PBF) AM processes. These processes led to ODS steels containing a high-density of nano-oxide dispersoids that enhance high-temperature mechanical properties. Such scalable, cost-effective fabrication of ODS steels can enable efficient power conversion cycles (=40%) at operating temperatures beyond 900 K in future fusion power plants.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Laser driven inertial fusion energy technology development

The future of Laser-Based Inertial fusion energy requires the development of efficient diode-pumped laser drivers that can be scaled to megajoule class output operating at ≥ 10-Hz repetition rate. ARPA-E requested a study of the range of possibilities for a 100kJ/10-Hz laser system with >15% wall-plug efficiency operating below 360 nm. The conceptual design of a compact, 1 kJ class module is presented and analyzed for performance relative to the objectives along with a roadmap to demonstrate the technology.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

High-Efficiency, High-Current Laser-Driven Electron Injector

This final report describes research conducted under DOE Award DE-SC0021132, "High-Efficiency, High-Current Laser-Driven Electron Injector," during the period 09/01/2020–08/31/2023. The project investigates a largely unexplored regime of short-pulse laser–plasma interaction near the quarter-critical density in ultrathin gas targets as a novel electron injection mechanism for laser–wakefield acceleration (LWFA). The overarching goal is to develop high-efficiency, high-current electron sources driven by modest peak-intensity lasers at high repetition rate, suitable as compact injectors or front-ends for future laser-based accelerators.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Surface Electronic Structure of Cr Doped Bi 2 Se 3 Single Crystals

Here, by using angle-resolved photoemission spectroscopy, we showed that Bi 2-x Cr x Se 3 single crystals have a distinctly well-defined band structure with a large bulk band gap and undistorted topological surface states. These spectral features are unlike their thin film forms in which a large nonmagnetic gap with a distorted band structure was reported. We further provide laser-based high resolution photoemission data which reveal a Dirac point gap even in the pristine sample. The gap becomes more pronounced with Cr doping into the bulk of Bi 2 Se 3 . These observations show that the Dirac point can be modified by the magnetic impurities as well as the light source.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Atmosphere Effects in Laser Powder Bed Fusion: A Review

The use of components fabricated by laser powder bed fusion (LPBF) requires the development of processing parameters that can produce high-quality material. Manipulating the most commonly identified critical build parameters (e.g., laser power, laser scan speed, and layer thickness) on LPBF equipment can generate acceptable parts for established materials and moderately intricate part geometries. The need to fabricate increasingly complex parts from unique materials drives the limited research into LPBF process control using underutilized parameters, such as atmosphere composition and pressure. As presented in this review, manipulating atmosphere composition and pressure in laser beam welding has been shown to expand processing windows and produce higher-quality welds. The similarities between laser beam welding and laser-based AM processes suggest that this atmosphere control research could be effectively adapted for LPBF, an area that has not been widely explored. Tailoring this research for LPBF has significant potential to reveal novel processing regimes. This review presents the current state of the art in atmosphere research for laser beam welding and LPBF, with a focus on studies exploring cover gas composition and pressure, and concludes with an outlook on future LPBF atmosphere control systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗