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NASA NTRS2016

Study of Material Consolidation at Higher Throughput Parameters in Selective Laser Melting of Inconel 718

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. SLM stands poised to revolutionize propulsion manufacturing, but there are a number of technical questions that must be addressed in order to achieve rapid, efficient fabrication and ensure adequate performance of parts manufactured using this process in safety-critical flight applications. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this work is to characterize the impact of higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. In phase I of this work, density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, hatch spacing, and layer thickness) and material consolidation (assessed in terms of as-built density and porosity). Phase II additionally considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the same higher energy parameter regime considered in the phase I work. Density and microstructure represent the "first-gate" metrics for determining the adequacy of the SLM process in this parameter range and, as a critical initial indicator of material quality, will factor into a follow-on DOE that assesses the impact of these parameters on mechanical properties. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.

Prater, Tracie↗

DOE OSTI2023

Hydrogen isotope analysis in W-tiles using fs-LIBS

Abstract Laser-Induced Breakdown Spectroscopy (LIBS) is a promising technology for in-situ analysis of Plasma-Facing Components in magnetic confinement fusion facilities. It is of major interest to monitor the hydrogen isotope retention i.e. tritium and deuterium over many operation hours to guarantee safety and availability of the future reactor. In our studies we use ultraviolet femtosecond laser pulses to analyze tungsten (W) tiles that were exposed to a deuterium plasma in the linear plasma device PSI-2, which mimics conditions at the first wall. A high-resolution spectrometer is used to detect the Balmer- $$\alpha$$ α transition of the surface from implanted hydrogen isotopes (H and D). We use Calibration Free CF-LIBS to quantify the amount of deuterium stored in W. This proof-of-principle study shows the applicability of femtosecond lasers for the detection of low deuterium concentration as present in first wall material of prevailing fusion experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Fast-charging lithium-ion batteries: Synergy of carbon nanotubes and laser ablation

Advancing lithium-ion battery (LiB) technology to achieve 10–15-min extreme fast charging (XFC) while maintaining high energy density and longevity poses a significant challenge. Addressing Li-plating is crucial, as it depletes useable Li, causing deterioration and safety issues. Here, this study explores a holistic approach incorporating Single-Wall Carbon Nanotubes (SWCNTs) and Laser Ablation (LA) to mitigate Li-plating while maintaining high charge acceptance under 10–15-min XFC. SWCNTs enhance the electrical conductivity and mechanical integrity of the positive electrode (PE), reducing overall cell overpotential at high charging rates. Concurrently, LA is applied to negative electrodes (NE) to reduce tortuosity of ion-diffusion pathways and increase surface wettability, improving Li-ion transport. Combining SWCNTs in the PE and LA on the NE, our experimental findings demonstrate a significant reduction in Li-plating and maintained high charge acceptance of ~84.33 % after 800 5C (12 min) charge cycles for cells having PE with ~3.3 mAh cm –2 and NE with 3.9 mAh cm –2 loadings. This study highlights the potential of combining SWCNTs and LA to address Li-plating in LiBs and opens new avenues for designing battery systems capable of achieving 10–15-min XFC.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1999

Quantitative Species Measurements in Microgravity Combustion Flames using Near-Infrared Diode Lasers

Understanding the physical phenomena controlling the ignition and spread of flames in microgravity has importance for space safety as well as for characterizing dynamical and chemical combustion processes which are normally masked by buoyancy and other gravity-related effects. Unfortunately, combustion is highly complicated by fluid mechanical and chemical kinetic processes, requiring the use of numerical modeling to compare with carefully designed experiments. More sophisticated diagnostic methods are needed to provide the kind of quantitative data necessary to characterize the properties of microgravity combustion as well as provide accurate feedback to improve the predictive capabilities of the models. Diode lasers are a natural choice for use under the severe conditions of low gravity experiments. Reliable, simple solid state operation at low power satisfies the operational restrictions imposed by drop towers, aircraft and space-based studies. Modulation wavelength absorption spectroscopy (WMS) provides a means to make highly sensitive and quantitative measurements of local gas concentration and, in certain cases, temperature. With near-infrared diode lasers, detection of virtually all major combustion species with extremely rapid response time is possible in an inexpensive package. Advancements in near-infrared diode laser fabrication technology and concurrent development of optical fibers for these lasers led to their use in drop towers. Since near-infrared absorption line strengths for overtone and combination vibrational transitions are weaker than the mid-infrared fundamental bands, WMS techniques are applied to increase detection sensitivity and allow measurement of the major combustion gases. In the first microgravity species measurement, Silver et al. mounted a fiber-coupled laser at the top of the NASA 2.2-sec drop tower and piped the light through a single-mode fiber to the drop rig. A fiber splitter divided the light into eight channels that directed the laser beam across a methane or propane diffusion jet flame. The light beams were recaptured by a set of gradient index lenses, coupled back into separate fiber optic lines, and transmitted back to detectors and electronics in the instrument package. In these experiments a 6-mm od fiber cable (containing the nine optical fibers) fell with the drop rig. Using separate detection and demodulation channels, spatial and temporal (up to 20 Hz) maps of water vapor and methane concentrations were obtained at differing heights in the flames. While this apparatus was useful from a demonstration standpoint, several drawbacks needed attention before useful scientific measurements could be obtained. First, eight lines of sight are somewhat insufficient for detailing the spatial profiles of the gas. Second, multiple detection channels operating in parallel are both expensive and present a challenge for accurate calibration. As a result, a newer scanning system was developed in our first contract under this program. The primary characteristic of this system is that it contains a single detection channel and achieves "continuous" spatial resolution by scanning the laser beam across the flame region, then directing this beam onto a single detector. Thus spatial measurements are converted to a temporal series of data. The true spatial resolution is limited only by the beam diameter and width of the sweep. In these experiments the beam is focused to about 1-mm diameter and scans across a region up to 4-cm wide.

Silver, Joel A.↗

NASA NTRS2002

Solid Freeform Fabrication: An Enabling Technology for Future Space Missions

The emerging class of direct manufacturing processes known as Solid Freeform Fabrication (SFF) employs a focused energy beam and metal feedstock to build structural parts directly from computer aided design (CAD) data. Some variations on existing SFF techniques have potential for application in space for a variety of different missions. This paper will focus on three different applications ranging from near to far term to demonstrate the widespread potential of this technology for space-based applications. One application is the on-orbit construction of large space structures, on the order of tens of meters to a kilometer in size. Such structures are too large to launch intact even in a deployable design; their extreme size necessitates assembly or erection of such structures in space. A low-earth orbiting satellite with a SFF system employing a high-energy beam for high deposition rates could be employed to construct large space structures using feedstock launched from Earth. A second potential application is a small, multifunctional system that could be used by astronauts on long-duration human exploration missions to manufacture spare parts. Supportability of human exploration missions is essential, and a SFF system would provide flexibility in the ability to repair or fabricate any part that may be damaged or broken during the mission. The system envisioned would also have machining and welding capabilities to increase its utility on a mission where mass and volume are extremely limited. A third example of an SFF application in space is a miniaturized automated system for structural health monitoring and repair. If damage is detected using a low power beam scan, the beam power can be increased to perform repairs within the spacecraft or satellite structure without the requirement of human interaction or commands. Due to low gravity environment for all of these applications, wire feedstock is preferred to powder from a containment, handling, and safety standpoint. The energy beams may be either electron beam or laser, and the developments required for either energy source to achieve success in these applications will be discussed.

Taminger, Karen M. B.↗

NASA NTRS1992

Earth to space power beaming: A new NASA technology initiative

Laser power beaming from the Earth's surface is an innovative and potentially cost-effective option for reliably providing electrical power for applications such as space transportation, Earth-orbiting satellites, and lunar development. The maturation of laser power beaming technology can support low power applications such as upgraded conventional communications satellites in the present decade. Power beaming systems to support extensive lunar base operations that may consume extremely large amounts of power can be implemented early in the 21st century. The synergistic advantages of high-thrust, high specific-impulse electric propulsion may make enhanced, low cost space logistics an area of unique significance for laser power beaming. Economic forces will continue as a driving factor in the selection of major system elements for both commercial applications as well as the avant-garde national space missions envisioned for the 21st century. As a result, the implementation of laser power beaming systems will only take place if they can demonstrate clear economic benefits without sacrificing performance, personnel safety, or the environment. Similarly, the development activities that are a necessary precursor to any operational system will take place only if key industry and government leaders perceive laser power beaming systems as an achievable goal with realistic payoffs in comparison to competing energy options. This paper summarizes NASA's current research to evaluate laser power beaming systems as they apply to applications of greatest interest, and it includes a summary of the current laser power beaming program within the NASA Headquarters Office of Aeronautics and Space Technology. This research effort will quantify some key technical certainties and uncertainties pertaining to laser power beaming systems appropriate for space applications as well as establish a path of development that includes maturation of key technology components for reliable laser and millimeter wave power beaming systems during the 1990's. The program is known as 'SELENE', an acronym for Space Laser Energy.

Rather, John D. G.↗

NASA NTRS2014

Five-Channel Infrared Laser Absorption Spectrometer for Combustion Product Monitoring Aboard Manned Spacecraft

Continuous combustion product monitoring aboard manned spacecraft can prevent chronic exposure to hazardous compounds and also provides early detection of combustion events. As future missions extend beyond low-Earth orbit, analysis of returned environmental samples becomes impractical and safety monitoring should be performed in situ. Here, we describe initial designs of a five-channel tunable laser absorption spectrometer to continuously monitor combustion products with the goal of minimal maintenance and calibration over long-duration missions. The instrument incorporates dedicated laser channels to simultaneously target strong mid-infrared absorption lines of CO, HCl, HCN, HF, and CO2. The availability of low-power-consumption semiconductor lasers operating in the 2 to 5 micron wavelength range affords the flexibility to select absorption lines for each gas with maximum interaction strength and minimal interference from other gases, which enables the design of a compact and mechanically robust spectrometer with low-level sensitivity. In this paper, we focus primarily on absorption line selection based on the availability of low-power single-mode semiconductor laser sources designed specifically for the target wavelength range.

Briggs, Ryan M.↗

NASA NTRSDate not supplied

Exploring the Use of a Ground-Based Laser System to Deorbit Small Orbital Debris

In March 2023, NASA Office of Technology, Policy, and Strategy (OTPS) released its Cost and Benefit Analysis of Orbital Debris Remediation report. This analysis found that the two most efficient methods for remediating orbital debris were the removal of small (1-10 cm) debris and nudging large debris away from predicted collisions; both methods could be performed by high-energy laser systems. To further explore the concept, OTPS has been assessing a reference mission using ground-based, pulsed lasers to detect, engage, and rapidly deorbit 1- to 10-cm debris that would otherwise threaten the safety of the International Space Station and future crewed platforms in low Earth orbit. In March of 2024, OTPS convened a technical interchange meeting (TIM) of experts in detection and tracking of debris, high-energy glass and excimer lasers, laser-matter interactions, atmospheric propagation, and adaptive optics. The TIM spanned two days, covering the unclassified state of the art, uncertainties, and technical challenges for the entire concept of operations of the reference mission. In this presentation, we will summarize the reference mission analyzed, key findings from the TIM, and solicit the feedback from this community to further define “what is good enough” for debris remediation.

orbital debris↗

NASA NTRS2014

NASA Tech Briefs, January 2014

Topics include: Multi-Source Autonomous Response for Targeting and Monitoring of Volcanic Activity; Software Suite to Support In-Flight Characterization of Remote Sensing Systems; Visual Image Sensor Organ Replacement; Ultra-Wideband, Dual-Polarized, Beam-Steering P-Band Array Antenna; Centering a DDR Strobe in the Middle of a Data Packet; Using a Commercial Ethernet PHY Device in a Radiation Environment; Submerged AUV Charging Station; Habitat Demonstration Unit (HDU) Vertical Cylinder Habitat; Origami-Inspired Folding of Thick, Rigid Panels; A Novel Protocol for Decoating and Permeabilizing Bacterial Spores for Epifluorescent Microscopy; Method and Apparatus for Automated Isolation of Nucleic Acids from Small Cell Samples; Enabling Microliquid Chromatography by Microbead Packing of Microchannels; On-Command Force and Torque Impeding Devices (OC-FTID) Using ERF; Deployable Fresnel Rings; Transition-Edge Hot-Electron Microbolometers for Millimeter and Submillimeter Astrophysics; Spacecraft Trajectory Analysis and Mission Planning Simulation (STAMPS) Software; Cross Support Transfer Service (CSTS) Framework Library; Arbitrary Shape Deformation in CFD Design; Range Safety Flight Elevation Limit Calculation Software; Frequency-Modulated, Continuous-Wave Laser Ranging Using Photon-Counting Detectors; Calculation of Operations Efficiency Factors for Mars Surface Missions; GPU Lossless Hyperspectral Data Compression System; Robust, Optimal Subsonic Airfoil Shapes; Protograph-Based Raptor-Like Codes; Fuzzy Neuron: Method and Hardware Realization; Kalman Filter Input Processor for Boresight Calibration; Organizing Compression of Hyperspectral Imagery to Allow Efficient Parallel Decompression; and Temperature Dependences of Mechanisms Responsible for the Water-Vapor Continuum Absorption.

Source record↗

NASA NTRS2016

Controlled Contamination of Epoxy Composites with PDMS and Removal by Laser Ablation

Surface preparation is critical to the performance of adhesively bonded composites. During manufacturing, minute quantities of mold release compounds are inevitably deposited on faying surfaces and may compromise bond performance. To ensure safety, mechanical fasteners and other crack arrest features must be installed in the bondlines of primary structures, which negates some advantages of adhesively bonded construction. Laser ablation is an automated, repeatable, and scalable process with high potential for the surface preparation of metals and composites in critical applications such as primary airframe structures. In this study, laser ablation is evaluated on composite surfaces for the removal of polydimethylsiloxane (PDMS), a common mold release material. Composite panels were contaminated uniformly with PDMS film thicknesses as low as 6.0 nm as measured by variable angle spectroscopic ellipsometry. Bond performance was assessed by mechanical testing using a 250 F cure, epoxy adhesive and compared with pre-bond surface inspection results. Water contact angle, optically stimulated electron emission, and laser induced breakdown spectroscopy were used to characterize contaminated and laser ablated surfaces. The failure mode obtained from double cantilever beam tests correlated well with surface characterization data. The test results indicated that even low levels of PDMS were not completely removed by laser ablation.

Palmieri, Frank↗

NASA NTRS1999

Radar Safety Interlock for a Remote Sensing System

A radar initiated interlock system which protects overflying aircraft from the laser radiation from the remote sensing systems located at Table Mountain Facility of the Jet Propulsion Laboratory is described in detail.

Radar Lidar↗

DOE OSTI2023

High-fidelity Experiments of Turbulent Buoyant Jets from Simultaneous Particle Image Velocimetry and Laser Induced Fluorescence

Accurate models of turbulent buoyant flows are essential for the design of nuclear reactors thermal hydraulics and passive safety systems. However, available models fail to fully capture the physics of turbulent mixing when buoyancy becomes predominant with respect to momentum. Therefore, high-fidelity experiments of well-controlled fundamental flows are needed to develop and validate more accurate models. We performed experiments of positive and negative turbulent buoyant jets, both in uniform and stratified environments, with the aim of understanding the thermal hydraulics of turbulent mixing with variable density and providing high-fidelity data for the development and validation of turbulence models. Non-intrusive, simultaneous Particle Image Velocimetry and Laser Induced Fluorescence measurements were carried out to acquire instantaneous velocity and concentration fields on a vertical section parallel to the axis of a jet in the self-similar region. The Refractive Index Matching method was applied to measure high-resolution buoyant jets with up to 8.6% density difference. These data are free of the typical errors that characterize optical measurements of buoyancy driven flows (e.g., natural and mixed convection) where the refractive index of the fluid is inhomogeneous throughout the measurement domain. Turbulent statistics and entrainment of buoyant jets in uniform and stratified environments are presented. These data are compared with non-buoyant jets in uniform environment, as a reference to investigate the effects of buoyancy and stratification on turbulent mixing. The results will be used for the assessment of current turbulence models and as basis for the development of a new one that captures turbulent mixing.

42 ENGINEERING↗

NASA NTRS1986

Visibility related to backscatter at 1.54 micron

The lidar process was shown to have the necessary potential to fulfill the need for a remote measurement of visibility. Visibility can be inferred from a lidar return optical extinction. The wavelength 1.54 micron was chosen, being near the visible wavelength region and having a high eye safety threshol, 200,000 times higher than 1.06 micron; 1.54 is the erbium laser wavelength. This research utilized 105 measured height profiles of natural droplet size distributions data, taken in clouds, fog, and haze. These profiles were examined to determine the completeness of the droplet counting data. It was found that the particle spectrometer data were incomplete in the very light ford and haze so this portion of the data was eliminated. Utilizing the Mie theory, these droplet size distribution profiles were converted to backscatter at 1.54 micron and extinction in the visible region, 0.55 micron. Using Koschmeider's relationship, the extinction profiles were converted to visibility. The visibility and backscatter profiles were compared to develop a relationship between visibility and backscatter at 1.54 micron.

Barber, T. L.↗

NASA NTRS1986

The NCAR Airborne Infrared Lidar System (NAILS)

A planned airborne lidar system is presented which is intended to provide a remote sensing facility for a variety of applications. The eventual goal of the system development is a Doppler wind measurement capability for boundary layer dynamics and cloud physics applications. The first stage of development is focused initially on a direct detection lidar to measure aerosol profiles and depolarization from cloud backscatter. Because of the Doppler goal, interest in larger particles to define the top of the mixed layer, and eye safety, the first stage of the system is based on a pulsed CO2 laser. A compact, relatively simple and inexpensive system that achieves flexibility to meet the data requirements of a variety of investigators by being easily modified rather than having many different capabilities built in is the goal. Although the direct detection sensitivity is less than that for heterodyne detection, the simpler system allows the achievement of useful scientific results and operating experience towards more complex lidars while staying within budget and time constraints.

Schwiesow, R. L.↗

DOE OSTI2021

Remote methane sensor for emissions from pipelines and compressor stations using chirped-laser dispersion spectroscopy

Leak rates of methane (CH 4 ) from the natural gas supply chain result in lost profit from unsold product, public safety and property concerns due to potential explosion hazards, and a potentially large source of economic damages from legal liabilities. Yet large measurement challenges exist in identifying and quantifying CH 4 leak rates along the vast number and type of components in the natural gas supply chain. This is particularly true of the “midstream” components involved in the gathering, processing, compression, transmission, and storage of natural gas. This project developed and deployed new advances in chirped laser dispersion spectroscopy (CLaDS) to detect methane leaks from pipelines, compressor stations, and other midstream infrastructure from a remote position (standoff detection). The system was deployed from a van to measure fugitive methane leaks from a local compressor station as a proof-of-concept. The technique was validated through mobile laboratory measurements with in-situ sensors as well as controlled releases of methane. The system also mapped a plume from a controlled release of methane by tracking a small unmanned aerial system (sUAS) that carried a corner cube retroreflector which reflected the beam back to the instrument. The drone-based system quantified a leak rate to within 30% of the actual rate and localized the emission location within 5 m of the actual release location at standoff distances of 25-45 m. This sUAS-reflector tracking approach has benefits for mapping leak locations remotely using small drones flying around a facility. Benefits of a commercial sensor with these capabilities include reductions of leaks for pipeline operators (more profit), earlier detection of leaks to avoid catastrophic explosion hazards for public health and to mitigate property damage, and reduced methane emissions to the atmosphere (improving air quality).

03 NATURAL GAS↗

NASA NTRS2013

Portable 4.6 Micrometers Laser Absorption Spectrometer for Carbon Monoxide Monitoring and Fire Detection

The air quality aboard manned spacecraft must be continuously monitored to ensure crew safety and identify equipment malfunctions. In particular, accurate real-time monitoring of carbon monoxide (CO) levels helps to prevent chronic exposure and can also provide early detection of combustion-related hazards. For long-duration missions, environmental monitoring grows in importance, but the mass and volume of monitoring instruments must be minimized. Furthermore, environmental analysis beyond low-Earth orbit must be performed in-situ, as sample return becomes impractical. Due to their small size, low power draw, and performance reliability, semiconductor-laser-based absorption spectrometers are viable candidates for this purpose. To reduce instrument form factor and complexity, the emission wavelength of the laser source should coincide with strong fundamental absorption lines of the target gases, which occur in the 3 to 5 micrometers wavelength range for most combustion products of interest, thereby reducing the absorption path length required for low-level concentration measurements. To address the needs of current and future NASA missions, we have developed a prototype absorption spectrometer using a semiconductor quantum cascade laser source operating near 4.6 micrometers that can be used to detect low concentrations of CO with a compact single-pass absorption cell. In this study, we present the design of the prototype instrument and report on measurements of CO emissions from the combustion of a variety of aerospace plastics.

Tunable Environmental Laser Spectrometer (TELS)↗

DOE OSTI2024

Laser-Induced Plasmas of Plutonium Dioxide in a Double-Walled Cell

Plutonium research has been stifled by the significant number of administrative controls and safety procedures, space and instrumentation limitations in radiological gloveboxes, and the potential for personnel and equipment contamination. To address the limited number of spectroscopic studies in Pu-bearing compounds in the current scientific literature, this work presents the use of double-walled cells (DWCs) in “clean” buildings/laboratories as an alternative to research in radiological gloveboxes. This study reports the first laser-induced breakdown spectroscopy (LIBS) experiments of a PuO 2 pellet contained within a DWC, where the formation of elemental (atomic and ionic) species as well as the evolution from elemental to molecular products (Pu x O y ) was measured. Raman spectroscopy was also used to characterize the surface of the ablated pellet and the particulates deposited on the window of the inner cell. The full width half-maximum of the T 2g band enabled us to obtain an estimate of the temperature at the pellet surface after the ablation pulse and the particulates based on the crystal lattice disorder. Particulates deposited on the window of the DWC during laser ablation were characterized using scanning electron microscopy, where molten irregular particulates and spheroids were observed. This exciting research conducted in a DWC describes our initial attempts to incorporate LIBS in the arsenal of spectroscopic tools for nuclear forensics applications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Optimization of laser-induced breakdown spectroscopy for liquid sodium analysis

Next-generation nuclear power reactors based on liquid sodium coolant are in development to improve efficiency and safety. Fast breeder reactors could potentially achieve considerably higher fuel burn-up while producing less nuclear waste compared with current commercial technology. Monitoring of impurities in these types of reactors is important in order to prevent blockage of the cooling system or hazardous reactions due to the high reactivity of sodium with water. In this work, laser-induced breakdown spectroscopy is performed on a liquid sodium sample using a custom-built immersion probe system. The probe provides direct line of sight to the sample vessel in argon atmosphere for laser delivery and signal collection. Signatures of sodium, and impurities such as potassium and oxygen have been obtained. The probe height and immersion have a strong influence on the signal level and stability. Argon flow rates of 2 to 5 liters per minute produce no substantial change in signal, suggesting a steady laminar flowing regime. A high signal-to-noise ratio for impurity elements confirms the suitability of this technique for reliable impurity detection and monitoring in the reactor environment.

Gardette, V. [University of Michigan, Ann Arbor, M↗