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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
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 OSTI2022

Sensor fusion of pyrometry and acoustic measurements for localized keyhole pore identification in laser powder bed fusion

We report in-situ process monitoring as an aid to part qualification for laser powder-bed fusion (L-PBF) technology is a topic of increasing interest to the additive manufacturing community. In this work, airborne acoustic and inline pyrometry measurements were recorded simultaneously with the laser position. X-ray radiography imaging was used to spatio-temporally register keyhole pore locations to the pyrometry and acoustic signals, enabling binary labeling of data partitions based on pore formation. These labeled partitions were subsequently featurized using a highly comparative time-series analysis toolbox. Acoustic data was found to be much more effective than the pyrometry data for keyhole pore identification. However, when the information contained in both sensing modalities was combined in a sensor fusion strategy, the error rates of the top performing models were significantly reduced.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

High-resolution in-situ characterization of laser powder bed fusion via transmission X-ray microscopy at X-ray free electron lasers

In this work, we describe the instrumentation used to perform the first operando transmission X-ray microscopy (TXM) and simultaneous X-ray diffraction of laser melting simulating laser powder bed fusion on the XCS instrument at the Linac Coherent Light Source (LCLS) X-ray free-electron laser (XFEL). Our TXM with 40× magnification in the X-ray regime at 11 keV gave spatial resolutions down to 940 nm per line pair, with effective pixel sizes down to 206 nm, image integration times of <100 fs, and frame rates tunable between 2.1 and 119 ns for two probe frames (0.48 GHz to 8.4 MHz). Images were recorded on Zyla and Icarus (UXI) detectors to trade off between spatial resolution and time dynamics. A 1 kW CW IR laser was coupled into the interaction point to conduct pump–probe studies of laser melting and solidification dynamics. Our temporal and spatial resolution with attenuation-based contrast exceeds that currently possible with synchrotron-based high-speed radiography. This system was sensitive to feature velocities of 10–12000 m s −1 but we did not observe any motion in this range in the laser melting of Al6061 alloy. Shockwaves were not observed and hot cracking proceeded at velocities below the detection limits. Pore accumulation was observed between successive shots, indicating that bubble escape mechanisms were not active. With proper experimental design, the spatial resolution, contrast and field of view could be further improved or modified. The increased brightness and narrower bandwidth of the XFEL allowed for this imaging technique and it lays the groundwork for a wide range of operando techniques to study additive manufacturing.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Formation mechanisms of Sn-rich δ phase and its role in strengthening Cu-10Sn manufactured by laser powder bed fusion

Cu-Sn alloys produced via laser powder bed fusion (L-PBF) additive manufacturing (AM) have gained significant attention because they combine the advantages of AM relevant to intricate component design with outstanding combinations of strength, ductility, and resistance to wear and corrosion. However, a detailed understanding of the microstructure that contributes to the enhancement of the mechanical properties of L-PBF Cu-10Sn alloys remains unclear. In particular, there is a lack of understanding of the formation mechanisms of the Sn-rich δ phase commonly observed in Cu-10Sn. This study reveals two distinct variants of the δ phase possessing unique morphological characteristics. These characteristics are attributed to the local solidification conditions inherent to the melt pool boundaries versus those at the interiors of melt pools. A phase transformation pathway that elucidates the origin of the morphological variants of the δ phase from the Sn-rich metastable phases during the cyclic heating of the AM process is proposed. We report superior mechanical properties in L-PBF Cu-10Sn compared to those of conventionally manufactured counterparts due to the synergistic contributions from grain boundaries, dislocations, and the δ phase. Notably, the δ phase alone contributes approximately 22 % to the overall strength observed in the L-PBF Cu-10Sn alloy. The discovery of two types of distinct Sn-rich δ phase offers key insights into precise microstructural control in AM Cu-Sn alloys to enhance mechanical properties, providing practical strategies for improving material performance for diverse applications in automotive, aerospace, and machinery industries.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Precipitation hardening of laser powder bed fusion Ti-6Al-4V

Here, the laser powder bed fusion (PBF-L) additive manufacturing (AM) community has dedicated significant efforts into process optimization and control for defect-free Ti-6Al-4V. As defects become less of an issue for PBF-L Ti-6Al-4V, the processing-structure-properties (PSP) relationships between AM microstructures can now be explored to optimize mechanical properties. Lower temperature aging treatments around 550 °C in wrought Ti-6A-4V have been historically understood to precipitation harden the α phase with an ordered, hexagonal close packed (HCP) α 2 phase. The α 2 phase existed as nanoscale Ti 3 Al precipitates coherent with the parent α phase. The goal of the present investigation was to implement a vacuum heat treatment of 545 °C for 100 hours on PBF-L Ti-6Al-4V. This vacuum heat treatment took place after an initial hot isostatic pressure (HIP) treatment that decomposed the as-built, martensitic microstructure. The vacuum aging successfully produced nanoscale precipitates of α 2 phase within α-laths, confirmed via atom probe tomography (APT). Microstructural-length scale and quasi-static mechanical properties were investigated by nanoindentation and uniaxial tensile tests of miniaturized test specimens. Given the sensitivity of Ti-6Al-4V mechanical properties to small changes in chemistry, all test specimens originated from the same build. The α 2 precipitation resulted in significantly harder α-laths (≈ 2 GPa) as measured via nanoindentation, as well as a relative yield and ultimate tensile strength increase of 60 MPa and 38 MPa, respectively. Analysis of Variance (ANOVA) of the datasets revealed no statistical differences in total elongation between the HIPed and HIPed + aged specimens, indicative of the aging treatment producing a net benefit of strength with no loss in ductility.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Laser Powder Bed Fusion Additive Manufacturing In-Process Monitoring and Optimization Using Thermionic Emission Detection

In this project, the emission of electrons during laser powder bed fusion additive manufacturing was identified and investigated to resolve the underlying dynamics driven by laser-material interactions. Laser powder bed fusion involves the selective laser melting of metal powder particles layer by layer which fuse together forming a larger 3D structure. Laser-based additive manufacturing approaches such as laser powder bed fusion hold the potential to revolutionize manufacturing of complex metal components in the aerospace, medical, and automotive industries. However, the difficulty in producing defect-free components by metal 3D printing is a major hurdle for widespread commercial adoption. This project resolved important dynamics in laser powder bed fusion including the identification of plasma formation mechanisms, transitions between laser-induced melting modes and stochastic precursors to defect formation. These findings were realized through implementation of electronic sensing diagnostics into an existing testbed system and harnessing capabilities developed for the time dependent analysis of laser powder bed fusion datasets. Importantly, the results advance our understanding of laser-material interactions and reveal that detection of thermionic emission can also resolve information critical to optimization of the laser powder bed fusion fabrication process. The findings are critical for advancing our fundamental understanding of the laser powder bed fusion process and can help assure the requisite fidelity of fabricated components.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Multimodal and multiscale strengthening mechanisms in Al-Ni-Zr-Ti-Mn alloy processed by laser powder bed fusion additive manufacturing

The unique thermokinetics of laser-powder bed fusion additive manufacturing (L-PBFAM) has been exploited for development of a novel high-strength Al-Ni-Ti-Zr-Mn alloy. The addition of 0.5 wt% Mn leads to extraordinary improvement in ultimate tensile strength (502 MPa) and work hardening due to the activation of two Mn-induced strengthening mechanisms. First, by a bimodal particle strengthening effect due to Al 31 Mn 6 Ni 12 nano-quasi-crystal particles rejected in inter-dendritic spaces and fibrous Al 3 Ni eutectic dendritic channels, which predominately contributes to the strength improvement, and second by solid solution strengthening from remaining Mn entrapped in Al. These mechanisms supplement the particle strengthening effect imparted by coherent and incoherent Al 3 (Ti,Zr) co-precipitates present at melt pool boundaries, dislocation strengthening due to solidification induced strain, and Hall-Petch and backstress strengthening effect due to heterogenous grain size distribution occurring at various length scales. In conclusion, the solidification dynamics and hierarchical heat distribution that are associated with L-PBFAM resulted in complex spatial variations in these strengthening phenomena and were investigated via a high-throughput multiscale structure–property correlation that involved thermokinetic simulation, X-ray diffraction, high-resolution nanoindentation mapping, and site-specific transmission electron microscopy of the alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A future of inertial confinement fusion without laser-plasma instabilities

From the beginning of inertial confinement fusion (ICF) research, laser-plasma instabilities excited by narrowband lasers have limited the hydrodynamic design space of all laser-based approaches to inertial fusion energy (IFE). With advances in broadband laser technologies, the next generation of ICF drivers will likely have large bandwidth that is engineered to mitigate laser-plasma instabilities, thereby expanding the hydrodynamic design space to include both robust high yields (>200−MJ) with large-energy laser systems (>4 MJ) and high gains (>10) with moderate-energy laser facilities (<2 MJ). State-of-the-art simulations indicate that laser bandwidths of a few percent are required to mitigate instabilities for IFE-relevant conditions. To test these models and demonstrate that high-bandwidth lasers mitigate laser-plasma instabilities, the Fourth-generation Laser for Ultrabroadband eXperiments will be used with the OMEGA Laser System. The goal is to provide the community with the confidence to invest in a multiple-beam high-bandwidth laser facility that will demonstrate the necessary ablation pressures for robust direct-drive ignition without detrimental levels of hot electrons that degrade the implosion performance. It is important to recognize that the highest performing ICF implosions will likely never be completely LPI free because of the significant advantages to maximizing the laser intensity.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

A new procedure for implementing the modified inherent strain method with improved accuracy in predicting both residual stress and deformation for laser powder bed fusion

As a metal additive manufacturing (AM) process, laser powder bed fusion (L-PBF) has been widely used to produce parts with complex geometries. The large thermal gradient caused by the fast, intense, and repeated laser scanning induces significant residual deformation and stress to the as-built parts, which increase manufacturing difficulty and geometrical inaccuracy as a result. The modified inherent strain (MIS) method exploiting multiscale process simulations was developed to simulate residual deformation accurately and efficiently. However, the existing procedure of implementing the MIS method is found to give inaccurate residual stress prediction. Here in this work, a new implementation procedure for the MIS method is proposed to improve the simulation accuracy of residual stress without degrading the residual deformation prediction. The new procedure concerns the application of inherent strains to the part-scale layer-by-layer finite element model to obtain residual stress and deformation field. While the existing implementation of the part-scale MIS model involves only mechanical properties at ambient temperature, the new procedure adds one more solution step employing mechanical properties at an elevated temperature determined from the inherent strain extraction step. Both numerical and experimental studies are conducted to validate the proposed new implementation procedure. It shows that by using the new procedure, the MIS-based simulation can predict both residual stress and deformation of as-built L-PBF metal parts with good accuracy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

In situ melt pool measurements for laser powder bed fusion using multi sensing and correlation analysis

Laser powder bed fusion is a promising technology for local deposition and microstructure control, but it suffers from defects such as delamination and porosity due to the lack of understanding of melt pool dynamics. To study the fundamental behavior of the melt pool, both geometric and thermal sensing with high spatial and temporal resolutions are necessary. This work applies and integrates three advanced sensing technologies: synchrotron X-ray imaging, high-speed IR camera, and high-spatial-resolution IR camera to characterize the evolution of the melt pool shape, keyhole, vapor plume, and thermal evolution in Ti–6Al–4V and 410 stainless steel spot melt cases. Aside from presenting the sensing capability, this paper develops an effective algorithm for high-speed X-ray imaging data to identify melt pool geometries accurately. Preprocessing methods are also implemented for the IR data to estimate the emissivity value and extrapolate the saturated pixels. Quantifications on boundary velocities, melt pool dimensions, thermal gradients, and cooling rates are performed, enabling future comprehensive melt pool dynamics and microstructure analysis. The study discovers a strong correlation between the thermal and X-ray data, demonstrating the feasibility of using relatively cheap IR cameras to predict features that currently can only be captured using costly synchrotron X-ray imaging. Such correlation can be used for future thermal-based melt pool control and model validation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. Here, we find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

Beam shaping↗
DOE OSTI2023

Effect of Volumetric Energy Density on Microstructure and Properties of Grade 300 Maraging Steel Fabricated by Laser Powder Bed Fusion

Here this study investigated the effect of laser powder bed fusion process parameters on the microstructure and properties of maraging steel. The results show that the process parameters can be finetuned to achieve both a high build rate/low hardness and low build rate/high hardness during fabrication, enabling the co-design of components where property gradients are desirable such as an injection molding tool where surface hardness is desired to be higher than the bulk, which needs to have higher fracture toughness.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Strain age cracking in a simulated heat affected zone of Inconel 740H laser-powder bed fusion components

Inconel® 740H components produced via laser-powder-bed fusion (L-PBF) additive manufacturing are ideal for supercritical CO2 primary heat exchangers. Arc welding is often needed, and subsequent post-weld heat treatment aging at 790–840 °C is required to improve strength via gamma prime (γ’) precipitation; however, strain age cracking (SAC) can occur in the heat affected zone (HAZ) during this process. This study uses stress relaxation testing at 800 °C on simulated HAZ specimens from vertically and horizontally built L-PBF IN740H to assess SAC susceptibility across heating rates of 40–3480 °C/h and weld-induced strains of 3–10 %. Vertical builds require greater mechanical energy input and exhibit longer times to fracture than horizontal builds, and time to fracture occurs sooner at slower heating rates. Creep voids were observed in γ’-denuded regions along grain boundaries, and cracking propagated along migrated grain boundaries and at interfaces between elongated secondary phases (γ’ or carbides) and the γ-matrix.

14 SOLAR ENERGY↗
DOE OSTI2025

Laser powder bed fusion parameter estimation with k-NN

Abstract Laser powder bed fusion (L-PBF) is a technique within additive manufacturing that uses a high power density laser to build parts from fused powdered metal alloy. This technology is well equipped to produce complex parts with otherwise impossible features, such as hidden voids or lattice structures. Alongside capability, reliability and quality are key characteristics considered when choosing a manufacturing method, and these are gaining attention as this method becomes more prevalent in industry. One main indicator of a stable L-PBF process is consistent melt pool geometry, and the properties of which are likely to determine the quality of the part produced. As computing power and sensing technologies become more advanced, this melt pool geometry could be studied in real time. This work addresses the challenge by leveraging a k-nearest neighbor (k-NN) model to identify key features within melt pool imagery and predict the energy density. The k-NN model was trained on data provided by the National Institute of Standards and Technology (NIST). Data preprocessing was performed on the images to extract features that were used in the k-NN model. This approach was used to accurately infer the energy density of unseen layers within the same part. The algorithm was subsequently tested with unique scan strategies and found to reasonably estimate the energy density of different parts. A fivefold cross validation found the algorithm to be consistently predicting the class of 91.4% of the in situ melt pool images.

Jung, Patrick (ORCID:0000000267890859)↗
DOE OSTI2024

An Electrical Resistance Diagnostic for Conductivity Monitoring in Laser Powder Bed Fusion

With the growing interest in metal additive manufacturing using laser powder bed fusion (LPBF), there is a need for advanced in-situ nondestructive evaluation (NDE) methods that can dynamically monitor manufacturing process-related variations, that can be used as a feedback mechanism to further improve the manufacturing process, leading to parts with improved microstructural properties and mechanical properties. Current NDE techniques either lack sensitivity beyond build layer, are costly or time-consuming, or are not compatible for in-situ integration. In this research, we develop an electrical resistance diagnostic for in-situ monitoring of powder fused regions during laser powder bed fusion printing. The technique relies on injecting current into the build plate and detecting voltage differences from conductive variations during printing using a simple, cheap four-point electrode array directly connected to the build plate. A computational model will be utilized to determine sensitivities of the approach, and preliminary experiments will be performed during the printing process to test the overall approach.

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↗
DOE OSTI2020

In Situ Analysis of Laser Powder Bed Fusion Using Simultaneous High-Speed Infrared and X-ray Imaging

Laser powder bed fusion is a metal additive manufacturing technique that has received significant scientific and industrial attention over the past decades. However, the quality and reproducibility of parts manufactured by this technique is still a problem. Overcoming this issue requires an understanding of multiple complex physical phenomena which occur simultaneously during the process. Here, we illustrate a powerful new technique which synchronizes high-speed x-ray imaging with high-speed infrared imaging to study laser powder bed fusion processes in real time. Using this technique, we demonstrate the simultaneous observation of multiple phenomena including three-dimensional melt pool visualization, vapor plume dynamics, spatter formation, thermal history, and point cooling rates. The paired observation of these dynamic phenomena is critical to understanding the fundamentals of laser powder bed fusion, and the overall impact of process parameters on print quality.

36 MATERIALS SCIENCE↗