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Electron-beam generator produces high quality welds without vaporization by relying on the mobility and hydrodynamic properties of the material in its liquid phase. The power density of the beam is relative to the speed of the workpiece, producing an inclined weld-front.
Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate an Inconel 718 bulk block deposit. Room temperature tensile properties were measured as a function of orientation and location within the block build. This study is a follow-on activity to previous work on Inconel 718 EBF3 deposits that were too narrow to allow properties to be measured in more than one orientation
Electron Beam Freeform Fabrication (EBF3) is an additive manufacturing technique, developed at NASA Langley Research Center, capable of fabricating large scale aerospace parts. Advantages of using EBF3 as opposed to conventional manufacturing methods include, decreased design-to-product time, decreased wasted material, and the ability to adapt controls to produce geometrically complex parts with properties comparable to wrought products. However, to fully exploit the potential of the EBF3 process development of materials tailored for the process is required. Powder cored tubular wire (PCTW) technology was used to modify Ti-6Al-4V and Al 6061 feedstock to enhance alloy content, refine grain size, and create a metal matrix composite in the as-solidified structures, respectively.
Electron beam welding selectively seals the outer surfaces of porous metal filters and impedances used in fluid flow systems. The outer surface can be sealed by melting a thin outer layer of the porous material with an electron beam so that the melted material fills all surface pores.
Attosecond pulses from free-electron lasers have opened the doors to atomic site-specific studies of bound electronic dynamics on their natural, sub-femtosecond timescales. Key to their success has been electron beam shaping techniques enabling the generation of sub-femtosecond current spikes with peak currents on the order of 10 kA. We demonstrate in an RF linac the generation of current spikes with extreme chirps on the order of 350 MeV/micron, directly competitive with the chirps expected from beam-driven plasma wakefield accelerators. Leveraging chirp-taper compensation, we use these highly chirped beams to generate hard X-ray attosecond pulses with bandwidths exceeding 30 eV, a factor of two beyond previous demonstrations. We simultaneously present the first explicit experimental evidence of chirp-taper compensation in an attosecond XFEL, finding that optimal tapering improves the bandwidth and pulse energy by factors of two and five, respectively, for our conditions. In addition to the immediate utility of such broadband hard X-ray pulses, electron beams with such extreme chirps can be utilized for unique new experimental modalities by performing further compression after the undulators. Such post-lasing compression can enable subsequent superradiant light emission at longer wavelengths, or direct excitation of quantum systems with the beam's intense space-charge field for unique attosecond pump-probe possibilities.
Using the potentials measured by the Spacelab's Charge and Current Probe during beam ejections and the signature of the harmonic emissions generated by pulsed electron beams, Neubert et al. (1988) presented evidence that overdense electron beams (with electron density above 150,000/cu cm) can escape the near vicinity of the Shuttle. This paper supplements these results by presenting a further indication of the beam escape and propagation out to at least 200 m, using the whistler-mode wave signature obtained during the SL-12 electron beam ejection which occurred on DOY 213 of 1985 from 03:30 to 03:37 UT. The combined results support the hypothesis that overdense electron beams can and will escape from a spacecraft, contrary to predictions based upon idealized simulations of the injection process.
The measurement of rotational temperature by the electron-beam fluorescence technique is investigated for temperatures between 78 K and 300 K by using the 0-0 band of the nitrogen first negative system. Existing methods for calculating the rotational temperature from electron-beam spectra result in values which are higher than the true temperature and the error increases with density and electron-beam current. The errors are believed to arise through neglect of the effects of secondary electrons. Excitation by low-energy secondary electrons can increase the population of the sparsely populated rotational ground states at the expense of the abundantly populated states. This secondary excitation is proposed as the cause of the error in the calculated rotational temperature and a theoretical study determines that the density and beam current govern the excitation rate. Rotational-temperature measurements are made in a flowing stream of nitrogen at a known temperature for a range of densities and beam currents.
Comparisons between flow visualization systems using electron-beam fluorescence, schlieren, and shadowgraph techniques illustrate the advantages associated with the electron beam. Specific applications of this method as an aid in defining the origin of erosion on a heat-transfer model are cited. Results of combined electron-beam oil-flow studies on configurations illustrate that the simultaneous definition of the external flow field and its surface flow can be obtained. Comparisons between the electron-beam oil-flow visualization method and phase-change coating heat-transfer tests on a shuttle ascent configuration indicate the complementary nature of these two testing techniques. Potential methods for improving the electron-beam technique are included.
A baseline concept for a continuous wave (CW) polarized positron injector was developed for the Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab. This concept is based on the generation of CW longitudinally polarized positrons by a high-current, polarized electron beam (1 mA, 130-370 MeV, and 90% longitudinal polarization) that passes through a rotating, water-cooled, tungsten target. The positron yield and longitudinal polarization are calculated for the 123 MeV Ce+BAF injector at the Low Energy Recirculator Facility (LERF). The longitudinal and transverse CEBAF acceptances, defined as an energy spread of less than 1% and a normalized emittance of less than 100 mm·mrad, have been used in these calculations. The impact of target thickness, transverse electron beam size, and electron beam energy on the yield and polarization of a positron injector is evaluated. The total energy deposited by the beams in the tungsten target and the peak energy density are calculated for different target thicknesses, electron beam sizes, and energies.
Current gathering rotating probe techniques were used to examine the envelope shape and power density profile of electron beams used in electron beam welding devices. The electron power density contours which determine the shape of the weld vapor cavity, penetration, and local heat distribution were considered. A mathematical analysis consistent with a rotating probe technique necessary to determine the current density distribution (assumed symmetrically radial) in a cross-section of the beam is provided. An explanation of the experimental technique for obtaining data, a BASIC language computer program to determine the current density from the data, and a study indicating the level of confidence to be associated with results obtained are also provided. An example of the application of the analysis to some experimental electron beam data is included.
Achieving strong focusing of MeV electron beams is a critical requirement for advanced beam applications such as compact laboratory x-ray sources, high gradient accelerators, and ultrafast electron scattering instrumentation. To address these needs, a compact radially magnetized permanent magnetic solenoid (PMS) has been designed, fabricated, and tested. The solenoid provides a compact and inexpensive solution for delivering high axial magnetic fields (1 T) to focus MeV electron beams. Field characterization of the solenoid demonstrates good agreement with analytical models, validating the PMS design. The electron beam test employs a high-brightness photoinjector to study the focusing properties of the PMS. The results indicate a focal length of less than 10 cm and a significant reduction in beam size with small spherical aberrations. Two application cases are evaluated: angular magnification in ultrafast electron diffraction setups and strong focusing for Compton scattering or other microfocus uses.
Electron beam (e-beam) generated plasmas with applied crossed electric and magnetic (E x B) fields are promising for low-damage (gentle) material processing. However, these plasmas can be subject to the formation of plasma non-uniformities propagating in the E x B direction. These rotating plasma structures (or “spokes”) enhance the transport of charged species across the magnetic field, which can harm the gentle processing capability of the plasma. In this work, we investigate the role of electrostatically active boundaries on the spoke formation by incorporating a variable bias conducting boundary (known as an anticathode) placed on the axially opposite side of the cathode. Our findings indicate azimuthal mode suppression occurs when the anticathode is electron collecting. Furthermore, we show selective azimuthal mode suppression by biasing the anticathode to an intermediate potential between the cathode and anode potentials. In conclusion, these findings suggest a link between the axial electron confinement in the e-beam generated plasma and azimuthally propagating plasma structure formation.
One-dimensional electrostatic particle simulations are used to investigate the injection and propagation of intense electron beams and the plasma response to the beam injection. Beam densities greater than about the plasma density are considered. It is shown that if the injection is continuous, most of the beam electrons are drawn back into the spacecraft because of the buildup of positive charge on the spacecraft. Those electrons which are able to propagate away from the spacecraft are emitted periodically because of space charge oscillations induced by electric fields associated with the beam. A substantial increase in the fraction and average energy of electrons which can propagate away can be obtained if the injection is changed to periodic pulses having width and period matched to the induced space charge oscillations.
This viewgraph presentation describes the effect of microgravity on the fabrication of electron beam freeform (EBF) in aerospace environments. The contents include: 1) Electron Beam Freeform Fabrication (EBF3) Process Description; 2) Portable Electron Beam Freeform Fabrication System at NASA LaRC; 3) Electron Beam Freeform Fabrication in the Space Environment; 4) Effect of Gravity on Surface Tension; 5) Effect of Deposit Height on Cooling Path; 6) Microgravity Testing Aboard JSC's C-9; 7) Typical Test Flight Plates; 8) Direction and Height Trials for Process Control; 9) Effect of Wire Entry Direction into Molten Pool; 10) Microstructure of Single Layer EBF Deposits; 11) 0-g Deposit with Incorrect Standoff Distance; 12) Successful Demonstration of EBF in 0-g; and 13) Conclusion.
The properties of radio waves generated by electron beams in space were investigated using data from the wideband wave receiver on the Spacelab 2. The VLF observations were found to confirm the results of the STS 3/OSS-1 mission. It was found that a 1-keV electron beam injected from the orbiter produced copious broadband electromagnetic emissions. When the electron beam was square-wave modulated, narrow-band emissions at the pulsing frequency and harmonics of that frequency were produced along with the broadband emissions. The observations indicated that dc 50-mA electron beams and pulsed 50-percent duty-cycle 100-mA beams produce broadband radiation which is comparable in intensity and spectral shape at all points for which the wave field was sampled.
Beam of an electron beam welder X rays its own welds, enabling rapid weld quality checks to be made without removing the work from the vacuum chamber. A tungsten target produces X rays when hit by the beam. They are directed at the weld specimen and recorded on polaroid film.
Here, we report theoretical calculations of plasma wave generation in the whistler modes and in the extraordinary modes, by pulsed electron beams in a magnetized plasma. The numerical simulations of the wave generation take into account the longitudinal expansion of the electron beam due to the space charge force and the energy spread. The work presented in this article provides predictions for the wave generation performance of the beam plasma interactions experiment (Beam PIE), where pulsed electron beams were produced by a spaceborne radio frequency (RF) linear accelerator. We also theoretically explore the desirable properties of the pulsed electron beam for future space experiments, which will be the next step toward eventually demonstrating the radiation-belt remediation (RBR).
An 8-kv electron beam with a current in the neighborhood of 100 mA from the Ukrainian space welding "Universal Hand Tool" (UHT) burned holes in Nextel AF-62 ceramic cloth designed to withstand temperatures up to 1,427 C. The burnthrough time was on the order of 8 scc at standoff distances between UHT and cloth ranging from 6-24 in. At both closer (2 in.) and farther (48 in.) standoff distances the potency of the beam against the cloth declined and the burnthrough time went up significantly. Prior to the test it had been expected that the beam would lay down a static charge on the cloth and be deflected without damaging the cloth. The burnthrough is thought to be an effect of partial transmission of beam power by a stream of positive ions generated by the high-voltage electron beam from contaminant gas in the "vacuum" chamber. A rough quantitative theoretical computation appears to substantiate this possibility.