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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A Bezier Curve Informed Melt Pool Geometry to Model Additive Manufacturing Microstructures Using SPPARKS

Additive manufacturing is a transformative technology with the potential to manufacture designs which traditional subtractive machining methods cannot. Additive manufacturing offers fast builds at near final desired geometry; however, material properties and variability from part to part remain a challenge for certification and qualification of metallic components. AM induced metallic microstructures are spatially heterogeneous and highly process dependent. Engineering properties such as strength and toughness are significantly affected by microstructure morphologies resulting from the manufacturing process Linking process parameters to microstructures and ultimately to the dynamic response of AM materials is critical to certifying and qualifying AM built parts and components and improving the performance of AM materials. The AM fabrication process is characterized by building parts layer by layer using a selective laser melt process guided by a computer. A laser selectively scans and melts metal according to a designated geometry. As the laser scans, metal melts, fuses, and solidifies forming the final geometry in a layerwise fashion. As the laser heat source moves away, the metal cools and solidifies forming metallic microstructures. This work describes a microstructure modeling application implemented in the SPPARKS kinetic Monte Carlo computational framework for simulating the resulting microstructures. The application uses Bzier curves and surfaces to model the melt pool surface and spatial temperature profile induced by moving the laser heat source; it simulates the melting and fusing of metal at the laser hot spot and microstructure formation and evolution when the laser moves away. The geometry of the melt pool is quite flexible and we explore effects of variances in model parameters on simulated microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Performance of Public Film Cooling Geometries Produced Through Additive Manufacturing

Abstract Film cooling is an essential cooling technology to allow modern gas turbines to operate at high temperatures. For years, researchers in this community have worked to improve the effectiveness of film cooling configurations by maximizing the coolant coverage and minimizing the heat flux from the hot gas into the part. Working toward this goal has generated many promising film cooling concepts with unique shapes and configurations. However, until recently, many of these designs were challenging to manufacture in actual turbine hardware due to limitations with legacy manufacturing methods. Now, with the advances in additive manufacturing, it is possible to create turbine parts using high-temperature nickel alloys that feature detailed and unique geometry features. Armed with this new manufacturing power, this study aims to build and test the promising designs from the public literature that were previously difficult or impossible to implement. In this study, different cooling hole designs were manufactured in test coupons using a laser powder bed fusion process. Each nickel alloy coupon featured a single row of engine scale cooling holes, fed by a microchannel. To evaluate performance, the overall cooling effectiveness of each coupon was measured using a matched Biot test at engine relevant conditions. The results showed that certain hole shapes are better suited for additive manufacturing than others and that the manufacturing process can cause significant deviations from the performance reported in the literature.

Engineering↗
DOE OSTI2023

Operando Temperature Measurements of Photovoltaic Laser Power Converter Devices Under Continuous High-Intensity Illumination

Photovoltaic devices that operate under extremely high irradiances, such as laser power converters (LPCs), may also operate at elevated temperatures, even under active cooling, as the result of large temperature gradients. We demonstrate the operation of GaAs LPC devices under orders of magnitude of irradiances up to 150 W/cm 2 in a monochromatic laser simulator with an active cooling stage. The steady-state open-circuit voltage (V OC ) as a function of irradiance is known to droop at high irradiance as the result of junction heating, but the junction temperature can be difficult to measure by conventional methods. Fast, transient V OC measurements under these extreme operating conditions are used here to determine the junction temperature. Empirical V OC temperature coefficients of the devices at each irradiance of interest are determined and used as an integral part of this technique. We show that the thermal design of different LPC devices strongly affects the operating temperature of the junctions. Knowledge of the operating temperature can be a strong tool for understanding the nature of loss mechanisms and improving the design for the operation of photovoltaic LPCs at high irradiances. Furthermore, this technique can be used for laboratory devices during initial design as well as to characterize mass-produced and packaged devices for quality control.

14 SOLAR ENERGY↗
DOE OSTI2020

Columnar-to-equiaxed transition in a laser scan for metal additive manufacturing

In laser powder bed fusion additive manufacturing (LPBFAM), different solidification conditions, e.g., thermal gradient and cooling rate, can be achieved by controlling the process parameters, such as laser power and laser speed. Tailoring the behaviour of the columnar to equiaxed transition (CET) of the printed alloy during fabrication can facilitate the production of highly customized microstructures. In this study, effective analytical solutions for both thermal conduction and solidification are employed to model solidifying melt pools. Microstructure textures and solidification conditions are evaluated for numerous combinations of laser power and laser speed under bead-on-plate conditions. This analytical-based high-throughput tool was demonstrated to select specific process parameters that lead to desired microstructures. Two selected process conditions were examined in detail by a highly parallelized microstructural solidification model to reveal both nucleation and grain growth. Both numerical solutions agree well with experiments that are performed based on bead-on-plate conditions, indicating that these numerical models aid evaluation of the nucleation parameters, providing insights for controlling CET during the LPBFAM processing.

Lang, Yuan↗
DOE OSTI2019

Simulations of coherent electron cooling with two types of amplifiers

The SPACE code is a parallel, relativistic, three-dimensional, electromagnetic, particle-in-cell code developed for the simulations of beam dynamics and interactions. The SPACE code can perform simulations with various beam distributions, different types of boundary conditions, and flexible beam line, as well as provide sufficient processing routines for data analyses and visualization. Finally, self-consistent, highly resolved and realistic simulations were performed using the SPACE code to study the coherent electron cooling (CeC) experiment with two types of amplifiers, the free electron laser (FEL) and plasma-cascade micro-bunching amplifiers.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Multiplexable high-temperature stable and low-loss intrinsic Fabry-Perot in-fiber sensors through nanograting engineering

This paper presents a method of using femtosecond laser inscribed nanograting as low-loss– and high-temperature–stable in-fiber reflectors. By introducing a pair of nanograting inside the core of a single-mode optical fiber, an intrinsic Fabry-Perot interferometer can be created for high-temperature sensing applications. The morphology of the nanograting inscribed in fiber cores was engineered by tuning the fabrication conditions to achieve a high fringe visibility of 0.49 and low insertion loss of 0.002 dB per sensor. Using a white light interferometry demodulation algorithm, we demonstrate the temperature sensitivity, cross-talk, and spatial multiplexability of sensor arrays. Both the sensor performance and stability were studied from room temperature to 1000°C with cyclic heating and cooling. Our results demonstrate a femtosecond direct laser writing technique capable of producing highly multiplexable in-fiber intrinsic Fabry-Perot interferometer sensor devices with high fringe contrast, high sensitivity, and low-loss for application in harsh environmental conditions.

Wang, Mohan (ORCID:0000000166784993)↗
DOE OSTI2020

Investigating off-Hugoniot states using multi-layer ring-up targets

Abstract Laser compression has long been used as a method to study solids at high pressure. This is commonly achieved by sandwiching a sample between two diamond anvils and using a ramped laser pulse to slowly compress the sample, while keeping it cool enough to stay below the melt curve. We demonstrate a different approach, using a multilayer ‘ring-up’ target whereby laser-ablation pressure compresses Pb up to 150 GPa while keeping it solid, over two times as high in pressure than where it would shock melt on the Hugoniot. We find that the efficiency of this approach compares favourably with the commonly used diamond sandwich technique and could be important for new facilities located at XFELs and synchrotrons which often have higher repetition rate, lower energy lasers which limits the achievable pressures that can be reached.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Cooling rate and dendrite spacing control in direct metal deposition printed Cu-Fe alloys

Over the last several decades, additive manufacturing (AM) has been primarily used for rapid prototyping or to create novel geometries that would be difficult or impossible to create by normal manufacturing methods. More recently, research has been focused on expanding the list of materials that can be made through additive manufacturing, opening a greater range of material properties for this manufacturing method. Due to the unusual conditions during AM, including the high cooling rates and voxel by voxel method of production, AM parts often have anisotropic material microstructures and properties. In this investigation, the laser power, composition, and nozzle head speed during direct metal deposition of copper-iron alloys was varied to understand how the grain structure within the printed parts could be changed and controlled. The resulting dendrite spacing was measured and compared to calculated cooling rates from Gaussian beams on flat plates under similar material and laser properties, which resulted in a cooling rate to dendrite spacing relationship following an inverse square root, as is found in other dendritic systems [Young and Kerkwood, Metall. Trans. A 6, 197–205 (1975)]. Thus, it is demonstrated that in the Cu-Fe system, dendrite spacing can be controlled through manipulation of printing parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Report for Pecos Activities (CY 2019)

All experiments involving the Pecos target chamber in calendar year (CY) 2019 were dedicated to Pre-Heat studies in the context of Magnetized Liner Inertial Fusion (MagLIF). Activities at the target area included actual laser shots but also diagnostic and maintenance, and preparatory work for experiments with cryogenically cooled targets, which are anticipated for CY 2020. Since the Z-Beamlet and Z-Petawatt lasers support multiple campaigns, we can only anticipate laser and laser-operator time for one out of three shot windows in a day, and typically not on every day of the week. For that reason, many of our non-shot activities need to be traded against shots as well.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Experimental Investigation of Innovative Cooling Schemes on an Additively Manufactured Engine Scale Turbine Nozzle Guide Vane

This study includes the design, validation, and fabrication via direct metal laser sintering (DMLS) of a gas turbine nozzle guide vanes (NGV) that incorporates three innovative cooling schemes specifically enabled by additive manufacturing. The novel NGV design is the culmination of an extensive research and development effort over a period of 4 years that included low- and high-speed cascade testing coupled with unsteady computational fluid dynamics for numerous candidate innovative cooling architectures. The final vane design (SJ-vane) consists of sweeping jet (SJ) film cooling holes on the suction surface (SS), sweeping jet impingement holes at the leading edge and double-wall partial length triangular pin-fin with impinging jet at the trailing edge. For comparison purposes, a second DMLS enabled vane (777-vane) was designed and fabricated with prototypical cooling circuits to serve as a baseline. This vane consists of a shaped film cooling holes on the suction surface, circular impingement holes at the leading edge, and full-length cylindrical pin-fins at the trailing edge. Experiments with the two DMLS enabled vanes were performed at the Ohio State University Turbine Reacting Flow Rig (TuRFR) at engine-relevant temperature (1375 K) and Mach number conditions. Infrared (IR) thermography was utilized to measure the wall temperature of the pressure and suction surface at several coolant mass flowrates to estimate the overall cooling effectiveness (ϕ). Results showed improved cooling performance for the advanced cooling schemes (sweeping jet film cooling, impingement cooling, and triangular pin-fin cooling) compared with the baseline cooling schemes.

Engineering↗
DOE OSTI2022

Strong yet ductile nanolamellar high-entropy alloys by additive manufacturing

Additive manufacturing produces net-shaped components layer by layer for engineering applications. The additive manufacture of metal alloys by laser powder bed fusion (L-PBF) involves large temperature gradients and rapid cooling, which enables microstructural refinement at the nanoscale to achieve high strength. However, high-strength nanostructured alloys produced by laser additive manufacturing often have limited ductility. In this work, we use L-PBF to print dual-phase nanolamellar high-entropy alloys (HEAs) of AlCoCrFeNi 2.1 that exhibit a combination of a high yield strength of about 1.3 gigapascals and a large uniform elongation of about 14 percent, which surpasses those of other state-of-the-art additively manufactured metal alloys. The high yield strength stems from the strong strengthening effects of the dual-phase structures that consist of alternating face-centred cubic and body-centred cubic nanolamellae; the body-centred cubic nanolamellae exhibit higher strengths and higher hardening rates than the face-centred cubic nanolamellae. The large tensile ductility arises owing to the high work-hardening capability of the as-printed hierarchical microstructures in the form of dual-phase nanolamellae embedded in microscale eutectic colonies, which have nearly random orientations to promote isotropic mechanical properties. The mechanistic insights into the deformation behaviour of additively manufactured HEAs have broad implications for the development of hierarchical, dual- and multi-phase, nanostructured alloys with exceptional mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A high efficiency and low vibration liquid nitrogen cooling system for silicon crystal based x-ray optics

A compact low-cost cryocooling system has been designed, constructed, and tested at SLAC National Accelerator Laboratory. The cooling power is provided by natural convection and phase change of the liquid nitrogen. The initial application was to cool silicon crystal optics to the sub-100 K range. A silicon crystal of dimension (width × depth × height) 50 × 50 × 30 mm3 has been used with an electric heater on the top surface in this prototyping test. This system can effectively provide more than 80 W of cooling power to the optics with a consumption of liquid nitrogen less than 2.1 l/h. The vibration of the silicon crystal was monitored during the tests with added electric heater power on the crystal. We note the vibration of the silicon crystal due to liquid nitrogen boiling is negligible.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Demonstration of thermal fracture limits of gas-cooled Nd:APG-1 and Tm:YLF slabs

High-energy short-pulse laser systems demonstrated to date have been limited to low repetition rates due to significant thermal management challenges associated with scaling these systems to high average power, including the need to understand the thermal fracture limits of laser gain media. In this paper, we demonstrate the thermal fracture limits of two high-average-power gain media in a realistic diode-pumped amplifier geometry: a 5 mm thick Nd:APG-1 slab and a 2 mm thick Tm:YLF slab, both cooled by room-temperature helium gas. Finite element analysis revealed maximum tensile stress at fracture of 25 ± 3 MPa for Nd:APG-1 and 30 ± 3 MPa for Tm:YLF. These stress levels correspond to average volumetric heat loads of 13 ± 1 W/cm 3 in Nd:APG-1 and 247 ± 12 W/cm 3 in Tm:YLF. Additional simulations show geometric scaling: thinner slabs tolerate higher heat loads before fracture, while larger pump spots reach the fracture stress at lower heat loads.

Lasers↗
DOE OSTI2025

Overcoming energy limitation in post-compression of picosecond pulses by free beam propagation in air and temporal pulse splitting and recombining

Cryogenically cooled diode-pumped Yb:YAG has been demonstrated to efficiently generate pulses of >1 J energy and several picoseconds duration at a kilohertz repetition rate. Pulse broadening and post-compression techniques capable of operating at these high pulse energies will expand the use of these lasers in applications requiring shorter pulses. Towards this goal, we demonstrate the post-compression of 5.5 ps pulses with energy in the 0.1 J range by spectral broadening of self-collimated large area beams in air. In proof-of-principle experiments, pulses of 65 mJ energy from a cryogenically cooled Yb:YAG laser were compressed to 1.1 ps after 65 m propagation in a compact setup in which the beam was folded using flat mirrors. Further energy scaling was demonstrated by combining this spectral broadening technique with temporal pulse splitting and recombining. 120 mJ pulses were split into two pulses and coherently recombined with 85% efficiency after 50 m of propagation in air to yield 1.4 ps pulses.

High Energy Laser↗
DOE OSTI2023

Laser heating and evaporation of a single droplet

The laser technology is being abundantly studied for controlled energy deposition for a range of applications in aerodynamic flow control, material processing, ignition, and combustion. The absorption of laser radiation by liquid droplets affects further propagation of laser in the atmosphere and causes bleaching of suspended droplets while the ignition and combustion characteristics in combustors are influenced by the evaporation rate of the sprayed fuel. In this work, we present a multi-dimensional mathematical model built on OpenFOAM for laser heating and evaporation of a single droplet in the diffusion dominated regime taking into account absorption of the laser radiation, evaporation process and vapor flow dynamics. The developed solver is validated against available experimental and numerical data for the ethanol and water droplet heating and evaporation. For continuous heating the peak temperature is established by the balance of cooling, evaporation and heating and results in high temperature for larger droplets. It has been shown that for heating by a single laser pulse the maximum temperature of droplets depends only on the peak intensity of the laser radiation. Furthermore, for the peak irradiance close to the transition to the boiling regime, temporal dynamics of the droplet temperature is independent of the droplet size. With proper normalization of time, the dynamics of the droplet shrinkage and cooling is shown to be independent of droplet sizes and peak laser intensities. The influence of cooling and evaporation processes on droplet heating was found to be controlled by the pulse repetition rate for repeated pulse operation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Melt-Pool Dynamics and Microstructure of Mg Alloy WE43 under Laser Powder Bed Fusion Additive Manufacturing Conditions

Magnesium-based alloy WE43 is a state-of-the-art bioresorbable metallic implant material. There is a need for implants with both complex geometries to match the mechanical properties of bone and refined microstructure for controlled resorption. Additive manufacturing (AM) using laser powder bed fusion (LPBF) presents a viable fabrication method for implant applications, as it offers near-net-shape geometrical control, allows for geometry customization based on an individual patient, and fast cooling rates to achieve a refined microstructure. In this study, the laser–alloy interaction is investigated over a range of LPBF-relevant processing conditions to reveal melt-pool dynamics, pore formation, and the microstructure of laser-melted WE43. In situ X-ray imaging reveals distinct laser-induced vapor depression morphology regimes, with minimal pore formation at laser-scan speeds greater than 500 mm/s. Optical and electron microscopy of cross-sectioned laser tracks reveal three distinct microstructural regimes that can be controlled by adjusting laser-scan parameters: columnar, dendritic, and banded microstructures. These regimes are consistent with those predicted by the analytic solidification theory for conduction-mode welding, but not for keyhole-mode tracks. The results provide insight into the fundamental laser–material interactions of the WE43 alloy under AM-processing conditions and are critical for the successful implementation of LPBF-produced WE43 parts in biomedical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Xenon Detection Using Double-Pulse Laser-Induced Breakdown Spectroscopy

Laser-induced breakdown spectroscopy has been proposed as a diagnostic tool for fuel failure monitoring in helium-cooled fast reactor designs. Here, we show preliminary results which indicate that using double-pulse laser induced breakdown spectroscopy, a sub-ppm sensitivity for xenon in a helium ambient can be achieved. We additionally propose future studies which could help elucidate the mechanisms which lead to the observed signal enhancement.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗