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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
NASA NTRS1998

Electron Beam Welder Used to Braze Sapphire to Platinum

A new use for electron beam brazing was recently developed by NASA Lewis Research Center's Manufacturing Engineering Division. This work was done to fabricate a fiberoptic probe (developed by Sentec Corporation) that could measure high temperatures less than 600 deg C of vibrating machinery, such as in jet engine combustion research. Under normal circumstances, a sapphire fiber would be attached to platinum by a ceramic epoxy. However, no epoxies can adhere ceramic fibers to platinum under such high temperatures and vibration. Also, since sapphire and platinum have different thermal properties, the epoxy bond is subjected to creep over time. Therefore, a new method had to be developed that would permanently and reliably attach a sapphire fiber to platinum. Brazing a sapphire fiber to a platinum shell. The fiber-optic probe assembly consists of a 0.015-in.-diameter sapphire fiber attached to a 0.25-in.-long, 0.059-in.-diameter platinum shell. Because of the small size of this assembly, electron beam brazing was chosen instead of conventional vacuum brazing. The advantage of the electron beam is that it can generate a localized heat source in a vacuum. Gold reactive braze was used to join the sapphire fiber and the platinum. Consequently, the sapphire fiber was not affected by the total heat needed to braze the components together.

Forsgren, Roger C.↗
NASA NTRS1983

Collisionless electron shocks in electron-beam-plasma systems

One-dimensional Vlasov simulations show that when an electron beam is suddenly injected into a plasma, a fast-moving monotonic shock forms during the early stage of the transient plasma response. In the shock, the ions are nearly immobile. The shock appears to be an electrostatic electron-beam-plasma mode. The shock evolves from an initial positive potential perturbation, which is supported by an ion burst. The steepening of the perturbation into a shock is characterized by an electron-beam-plasma mode.

Singh, N.↗
NASA NTRS1995

Energy measurement of electron beams by Compton scattering

A method has been proposed to utilize the well-known Compton scattering process as a tool to measure the centroid energy of a high energy electron beam at the 0.01% level. It is suggested to use the Compton scattering of an infrared laser off the electron beam, and then to measure the energy of the scattered gamma-rays very precisely using solid-state detectors. The technique proposed is applicable for electron beams with energies from 200 MeV to 16 GeV using presently available lasers. This technique was judged to be the most viable of all those proposed for beam energy measurements at the nearby Continuous Electron Beam Accelerator Facility (CEBAF). Plans for a prototype test of the technique are underway, where the main issues are the possible photon backgrounds associated with an electron accelerator and the electron and laser beam stabilities and diagnostics. The bulk of my ASEE summer research has been spent utilizing the expertise of the staff at the Aerospace Electronics Systems Division at LaRC to assist in the design of the test. Investigations were made regarding window and mirror transmission and radiation damage issues, remote movement of elements in ultra-high vacuum conditions, etc. The prototype test of the proposed laser backscattering method is planned for this December.

Keppel, Cynthia↗
NASA NTRS1988

Double-probe potential measurements near the Spacelab 2 electron beam

As part of the Spacelab 2 mission the plasma diagnostics package (PDP) was released from the shuttle as a free-flying satellite. The PDP carried a quasi-static electric field instrument which made differential voltage measurements between two floating probes. At various times during the free flight, an electron beam was ejected from the shuttle. Large differential voltages between the double probes were recorded in association with the electron beam. However, analysis indicates that these large signals are probably not caused by ambient electric fields. Instead, they can be explained by considering three effects: shadowing of the probes from streaming electrons by the PDP chassis, crossing of the PDP wake by the probes, and spatial gradients in the fluxes of energetic electrons reaching the probes. Plasma measurements on the PDP show that energetic electrons exist in a region 20 m wide and up to at least 170 m downstream from the electron beam. At 80 or more meters downstream from the beam, the double probe measurements show that the energetic electron flux is opposite to the injection direction, as would be expected for a secondary returning electron beam produced by scattering of the primary electron beam.

Steinberg, J. T.↗
NASA NTRS2016

In-Process Thermal Imaging of the Electron Beam Freeform Fabrication Process

Researchers at NASA Langley Research Center have been developing the Electron Beam Freeform Fabrication (EBF3) metal additive manufacturing process for the past 15 years. In this process, an electron beam is used as a heat source to create a small molten pool on a substrate into which wire is fed. The electron beam and wire feed assembly are translated with respect to the substrate to follow a predetermined tool path. This process is repeated in a layer-wise fashion to fabricate metal structural components. In-process imaging has been integrated into the EBF3 system using a near-infrared (NIR) camera. The images are processed to provide thermal and spatial measurements that have been incorporated into a closed-loop control system to maintain consistent thermal conditions throughout the build. Other information in the thermal images is being used to assess quality in real time by detecting flaws in prior layers of the deposit. NIR camera incorporation into the system has improved the consistency of the deposited material and provides the potential for real-time flaw detection which, ultimately, could lead to the manufacture of better, more reliable components using this additive manufacturing process.

Taminger, Karen M.↗
NASA NTRS1996

Particulate electron beam weld emission hazards in space

The electron-beam welding process is well adapted to function in the environment of space. The Soviets were the first to demonstrate welding in space in the mid-1980's. Under the auspices of the International Space Welding Experiment (ISWE), an on-orbit test of a Ukrainian designed electron-beam welder (the Universal Hand Tool or 'UHT') is scheduled for October of 1997. The potential for sustained presence in space with the development of the international space station raises the possibility of the need for construction and repair in space. While welding is not scheduled to be used in the assembly of the space station, repair of damage from orbiting debris or meteorites is a potential need. Furthermore, safe and successful welding in the space environment may open new avenues for design and construction. The safety issue has been raised with regard to hot particle emissions (spatter) sometimes observed from the weld during operations. On earth the hot particles pose no particular hazard, but in space there exists the possibility for burn-through of the space suit which could be potentially lethal. Contamination of the payload bay by emitted particles could also be a problem.

Bunton, Patrick H.↗
NASA NTRS1991

Nonlinear wave scattering and electron beam relaxation

The role played by nonlinear scattering during the relaxation of a warm electron beam is investigated through a numerical code based on kinetic equations. The code encompasses the quasi-linear wave-electron interaction and wave-wave scattering off ion clouds. Ions with velocities 2 nu sub i (nu sub i being the ion thermal velocity) are found to be the most efficient for scattering the Langmuir waves off their polarization clouds. The transfer rate of the spectrum out of resonance with the beam is larger by a factor 3 compared to usual estimates. The changes produced in the dispersion relation by the presence of the beam electrons dramatically alter the characteristics of the secondary spectrum. In a late phase the classic condensate K of about 0 is depleted, with the formation of a new condensate in resonance with the flat-topped beam distribution, which follows from the fact that the mere presence of the beam electrons creates a minimum in the frequency-wave-number relation. For strong and slow beams, the predictions of the code are found to be in excellent agreement with the results of the particle simulation if a dispersion relation that includes the beam is used.

Muschietti, L.↗
DOE OSTI2025

Single-Shot Reconstruction of Electron Beam Longitudinal Phase Space in a Laser Wakefield Accelerator

We report on a single-shot longitudinal phase-space reconstruction diagnostic for electron beams in a laser wakefield accelerator via the experimental observation of distinct periodic modulations in the angularly resolved spectra. Such modulated angular spectra arise as a result of the direct interaction between the ultrarelativistic electron beam and the laser driver in the presence of the wakefield. A constrained theoretical model for the coupled oscillator, assisted by a genetic algorithm, can recreate the experimental electron spectra and, thus, fully reconstructs the longitudinal phase-space distribution of the electron beam with a temporal resolution of approximately 1.3 fs. In particular, it reveals the slice energy spread of the electron beam, which is important to measure for applications such as x-ray free electron lasers. In our experiment, the root-mean-square energy spread retrieved is bounded at 9.9 MeV, corresponding to a 0.9%–3.0% relative spread, despite the overall GeV energy beam having approximately 100% relative energy spread.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1996

Excitation of Plasma Waves in Aurora by Electron Beams

In this paper, we study numerically the excitation of plasma waves by electron beams, in the auroral region above 2000 km of altitude. We have solved the fully kinetic dispersion relation, using numerical method and found the real frequency and the growth rate of the plasma wave modes. We have examined the instability properties of low-frequency waves such as the Electromagnetic Ion Cyclotron (EMIC) wave as well as Lower-Hybrid (LH) wave in the range of high-frequency. In all cases, the source of free energy are electron beams propagating parallel to the geomagnetic field. We present some features of the growth rate modes, when the cold plasma parameters are changed, such as background electrons and ions species (H(+) and O(+)) temperature, density or the electron beam density and/or drift velocity. These results can be used in a test-particle simulation code, to investigate the ion acceleration and their implication in the auroral acceleration processes, by wave-particle interaction.

daSilva, C. E.↗
DOE OSTI2026

Integrated Strategies for Overcoming Resolution Limits in Electron Beam Lithography of Chemically Amplified Resists

Electron beam lithography (EBL) of chemically amplified resists (CARs) faces fundamental challenges, including stochastic electron scattering and acid diffusion, that limit resolution and reproducibility. Using SU-8 as a model CAR, this study systematically investigated complementary strategies to address these challenges, combining multipass exposure, proximity effect correction (PEC) with midrange correction factors, base quencher incorporation, and post-exposure bake (PEB) suppression. Monte Carlo simulations and calibrated PEC modeling revealed that extending the point spread function to include a midrange scattering component significantly improved critical dimension (CD) control across varying pattern densities, correcting deviations that conventional two-term PEC failed to capture. Multipass exposure, particularly 4-pass writing with a 25% offset, redistributed the dose to average stochastic beam and scattering fluctuations, reducing line-width roughness by more than 50% and yielding more uniform nanoscale features. Photoacid confinement was investigated by adding urea as a base quencher, which successfully reduced acid diffusion but introduced substantial sensitivity penalties without improving ultimate resolution or Z-factor performance, underscoring the trade-offs of chemical versus physical confinement. Suppressing PEB most directly minimized acid diffusion, resulting in improved Z-factors and reproducible 30 nm half-pitch dense line/space patterns. Overall, these results demonstrated that PEC with midrange correction, multipass strategies, quencher additives, and PEB-free processing addresses different aspects of the EBL process window and that their integration provides a comprehensive framework for managing stochastic scattering, diffusion, and chemical amplification effects. This framework advances dense nanoscale patterning in CARs and establishes guiding principles for optimizing resist design and process strategies in high-resolution EBL and potentially other advanced lithographies, such as extreme ultraviolet (EUV) lithography.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Evaluation of current density measurement methods for high-current, low-beta electron beams

Recent current density measurements with a low-beta electron beam (β=0.5-0.75) are strongly affected by electron scatter and Cherenkov limits. These invasive measurements are heavily influenced by the electron energy and the intercepting material properties: density, index of refraction, and atomic number. We evaluate various measurement methods, including x-ray scintillation and Cherenkov emission. To optimize the x-ray scintillation technique for this energy regime, metal foils of differing atomic number (Z) and thickness were placed upstream of a scintillation screen. We have selected Cherenkov emitters, based on a material refractive index, in order to differentiate the contributions from electron scatter and produced fluorescence, Cherenkov emission, and total internal reflection. The observed distributions for both approaches are verified through MCNP6®. Additionally, the simulations provide insight as to what physical processes dominate the measured distribution. We conclude by determining the limits and optimal measurement range for each measurement technique.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Experimental Generation of Extreme Electron Beams for Advanced Accelerator Applications

In this Letter, we report on the experimental generation of high energy (10 GeV), ultrashort (femtosecond-duration), ultrahigh current (∼ 0.1 MA), petawatt peak power electron beams in a particle accelerator. These extreme beams enable the exploration of a new frontier of high-intensity beam-light and beam-matter interactions broadly relevant across fields ranging from laboratory astrophysics to strong field quantum electrodynamics and ultrafast quantum chemistry. We demonstrate our ability to generate and control the properties of these electron beams by means of a laser-electron beam shaping technique. In conclusion, this experimental demonstration opens the door to on-the-fly customization of extreme beam current profiles for desired experiments and is poised to benefit a broad swath of cross-cutting applications of relativistic electron beams.

43 PARTICLE ACCELERATORS↗
NASA NTRS1965

Electron-beam deflection controlled by digital signals

Electron-beam deflection in electronic image converters is controlled by a tapped magnetic deflection yoke and a series of current generators. The generators supply equal current to each tap through digitally controlled switches, thereby increasing the inherent accuracy of the system.

Cressey, J. R.↗
DOE OSTI2026

Bubble explosion induced melt pool instabilities in electron beam melting of aluminum alloy

Electron beam melting (EBM) is an additive manufacturing technology that can process materials and manufacture components otherwise impossible or uneconomical. However, defects, including porosity and surface irregularities, are widely reported in EBM-built components, and their formation mechanisms are not fully understood. Here, using in-situ high-speed synchrotron X-ray imaging, we reveal that bubble explosions in Al6061 during EBM induce melt pool instabilities contributing to defect formation. The melt pool and keyhole evolve through three stages: (1) initial formation of a melt pool, (2) subsurface bubble formation and explosion, and (3) periodic keyhole oscillation. During scanning, periodic bubble explosions can eject molten liquid as spatters and disturb the vapor depression and melt pool, contributing to surface humping, that may trigger lack-of-fusion defects in subsequent layers. The physical insights we report could provide guidance for EBM machine development, process innovation, alloy design and model development.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Quantifying Trapped Powder in Electron Beam Powder Bed Fusion

Abstract Electron beam powder bed fusion (PBF-EB) shows great potential for manufacturing complex parts including those with internal cavities for heat exchanger, manifold systems, or energy absorption purposes. PBF-EB allows for the manufacture of channel geometries without the need for support structures. Due to the nature of the powder spreading process, powder feedstock is often trapped in intentionally manufactured cavities. This trapped powder can often be difficult to remove and can disturb the intended flow of fluid through the cavity or damage downstream components in its use case. These trapped powder particles present a risk of contamination and component failure if not completely evacuated. Ti6Al4V is a choice material for aerospace applications due to its high strength to weight ratio and its composition as a nonferrous metal; however, in weight sensitive applications excess entrapped powders or powders loosely attached to the surface could cause undesirable weight increases. The inherent spreading process of PBF-EB is different than laser powder bed fusion (PBF-LB) in its operational temperature, sintering. In addition, PBF-EB is less commonly studied in literature compared to its PBF-LB counterpart, and as a result the complexity of the semi-sintered powder and its spreading behavior are not well understood. Prior work has investigated the difficulty in removing trapped powder from PBF-EB, but these studies do not address how to quantify the amount of trapped powder in the cavity. Thus, an accurate method to measure the amount of trapped powder in the cavity must be investigated. In this work, Ti6Al4V coupons were manufactured with horizontal and vertical cavities of three different sizes. Archimedes testing allows for the determination of density differences caused by porosity and trapped powders by measuring mass and volumetric dispersion. Computed tomography (CT) is well suited for segmenting the internal structure and features of a part and has been studied for applications including voids, porosity, and dross. Thus, CT was explored as a method for evaluating trapped powder content in this work. The volumetric representation of the segmentation of the reconstructed CT volume can vary greatly depending on the input filter and thresholding methods. In this study, four different types of segmentation approaches were evaluated to determine the best approach for segmenting the volume as compared to an operator labeled ground truth. The percentage density results from the Archimedes testing were compared to the volumetric percent density from the computed tomography approach. Differences in packing density between two different internal channel features were investigated. Overall, this work sought to validate the use of computed tomography for the detection of trapped powders and present a framework for volumetric segmentation.

Johnstone, Brian↗