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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Resonance excitation of surface capillary waves to enhance material removal for laser material processing

Abstract The results of detailed experiments and high fidelity modeling of melt pool dynamics, droplet ejections and hole drilling produced by periodic modulation of laser intensity are presented. Ultra-high speed imaging revealed that melt pool oscillations can drive large removal of material when excited at the natural oscillation frequency. The physics of capillary surface wave excitation is discussed and simulation is provided to elucidate the experimental results. The removal rates and drill through times as a function of driving frequency is investigated. The resonant removal mechanism is driven by both recoil momentum and thermocapillary force but the key observation is the latter effect does not require evaporation of material, which can significantly enhance the efficiency for laser drilling process. We compared the drilling of holes through a 2 mm-thick Al plate at modulation frequencies up to 20 kHz. At the optimal frequency of 8 kHz, near the resonant response of the melt pool, the drilling efficiency is greater than 10x with aspect ratio of 12:1, and without the collateral damage that is observed in unmodulated CW drilling.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Accurate and efficient predictions of keyhole dynamics in laser materials processing using machine learning-aided simulations

The keyhole phenomenon has been widely observed in laser materials processing, including laser welding, remelting, cladding, drilling, and additive manufacturing. Keyhole-induced defects, primarily pores, dramatically affect the performance of final products, impeding the broad use of these laser-based technologies. The formation of these pores is typically associated with the dynamic behavior of the keyhole. So far, the accurate characterization and prediction of keyhole features, particularly keyhole depth, as a function of time, has been a challenging task. In situ characterization of keyhole dynamic behavior using the synchrotron X-ray technique is informative but complicated and expensive. Current simulations are generally hindered by their poor accuracy and generalization abilities in predicting keyhole depths due to the lack of accurate laser absorptance data. In this study, we develop a machine learning-aided simulation method that accurately predicts keyhole dynamics, especially in keyhole depth fluctuations, over a wide range of processing parameters. In two case studies involving titanium and aluminum alloys, we achieve keyhole depth prediction with a mean absolute percentage error of 10 %, surpassing those simulated using the ray-tracing method with an error margin of 30 %, while also reducing computational time. This exceptional fidelity and efficiency empower our model to serve as a cost-effective alternative to synchrotron experiments. Our machine learning-aided simulation method is affordable and readily deployable for a large variety of materials, opening new doors to eliminate or reduce defects for a wide range of laser materials processing techniques.

Computational fluid dynamics↗
DOE OSTI2024

Exploring laser-material interactions of zirconium carbide under additive manufacturing conditions

Zirconium carbide (ZrC) is an ultra-high temperature ceramic with a melting temperature above 3000°C and a broad range of high temperature applications. Given the high melting and sintering temperatures of pure ZrC, producing near-net shape and fully dense parts remains challenging with conventional techniques. In this study, we investigate the fundamental laser-material interactions of ZrC under laser powder bed fusion (LPBF) additive manufacturing (AM) conditions. Normalized enthalpy, a scaling law term that is used in welding and AM literature for detailing laser-material interactions in metallic alloys, was calculated to determine the predictive capabilities of melt pool features in ZrC. Further, the melt pool quality of laser irradiated ZrC was used to compare LPBF relevant laser parameter combinations of laser power, scan speed, and beam diameter. Laser build parameters that resulted in desirable melt pool morphologies were applied to the fabrication of ZrC coupons using LPBF AM. A custom LPBF system was used to determine hatch spacing and layer height parameters that resulted in a fabricated sample with a density of 85% as measured by Archimedes and a Vicker's microhardness of 20.9 ± 1.9 GPa. This investigation reveals the laser-material interactions of ZrC under AM relevant conditions and is the first step towards LPBF fabrication of ZrC parts.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A review of laser materials processing paradigms

Laser-based processing of materials has progressed from traditional applications such as macroscale cutting and welding, to sophisticated techniques, including ultrafast micromachining, additive manufacturing, and surface engineering at micro- and nano-metric scales. Innovations in laser source technology, particularly the advent of high-power and ultrashort-pulse lasers, have expanded the range of processable materials, enabled a plethora of manufacturing applications, and propelled groundbreaking research in optics, photonics, electronics, and biomedical domains. In this article, we provide a concise, yet broad review of the congruent evolution of lasers and materials processing, and highlight seminal developments in the field over the years, combined with a critical assessment of the state of the art. Finally, we also provide an outlook on emerging needs, as well as a roadmap of anticipated developments in laser technologies and materials platforms over the next 50 years.

Lasers↗
DOE OSTI2016

Laser-material interaction during atom probe tomography of oxides with embedded metal nanoparticles

Here, oxide-supported metal nano-particles are of great interest in catalysis but also in the development of new large-spectrum-absorption materials. The design of such nano materials requires three-dimensional characterization with a high spatial resolution and elemental selectivity. The laser assisted Atom Probe Tomography (La-APT) presents both these capacities if an accurate understanding of laser-material interaction is developed. In this paper, we focus on the fundamental physics of field evaporation as a function of sample geometry, laser power, and DC electric field for Au nanoparticles embedded in MgO. By understanding the laser-material interaction through experiments and a theoretical model of heat diffusion inside the sample after the interaction with laser pulse, we point out the physical origin of the noise and determine the conditions to reduce it by more than one order of magnitude, improving the sensitivity of the La-APT for metal-dielectric composites.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Fundamentals of ultrafast laser–material interaction

Short pulse laser irradiation has the ability to bring a material into a state of strong electronic, thermal, phase, and mechanical nonequilibrium and trigger a sequence of structural transformations leading to the generation of complex multiscale surface morphologies, unusual metastable phases, and microstructures that cannot be produced by any other means. In this article, we provide an overview of recent advancements and existing challenges in the understanding of the fundamental mechanisms of short pulse laser interaction with materials, including the material response to strong electronic excitation, ultrafast redistribution and partitioning of the deposited laser energy, the peculiarities of phase transformations occurring under conditions of strong superheating/undercooling, as well as laser-induced generation of crystal defects and modification of surface microstructure.

Materials Science↗
DOE OSTI2016

Laser material processing with tightly focused cylindrical vector beams

We demonstrate a comprehensive modification study of silica glass, crystalline silicon, and amorphous silicon film, irradiated by tightly focused cylindrical vector beams with azimuthal and radial polarizations. The evidence of the longitudinal field associated with radial polarization is revealed by second harmonic generation in z-cut lithium niobate crystal. Despite the lower threshold of ring-shaped modification of silicon materials, the modification in the center of single pulse radially polarized beam is not observed. The phenomenon is interpreted in terms of the enhanced reflection of longitudinal component at the interface with high-index contrast, demonstrating that the longitudinal component is inefficient for the flat surface modification. Enhanced interaction of the longitudinal light field with silicon nanopillar structures produced by the first pulse of double-pulse irradiation is also demonstrated.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Laser material interactions in tamped materials on picosecond time scales in aluminum

Here, a 100 ps laser is used to probe the pressure generation, depth of the non-solid ablator, and the non-linear optical effects through tamper materials. Samples consisted of an aluminum ablator with tampers of sapphire and coverslip glass. In general, the sapphire tamped sample achieves higher pressures at lower laser intensities as compared to the coverslip glass tamped sample. Attempts to model the details of this set of experimental data with standard available radiation coupled hydrodynamic codes make clear that more physics is needed in these simulations to accurately predict the impact of the tamper material on the pressure generation and the depth of non-solid aluminum.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Dynamic beam shaping—Improving laser materials processing via feature synchronous energy coupling

Today, tailored laser beams are rarely used and thus an opportunity to optimize existing or introduce new processes is missed. New methods of dynamic beam shaping have the potential to change that in future. This keynote paper deals with methods allowing a transient energy input into the workpiece at such time scales that the underlying interaction processes are guided towards the desired result. It shows principles, categorizes necessary system technology, and gives application examples to familiarize the reader with the topic. It postulates that time-scale-dependent coupling between transient energy input and addressed process features is key for achieving the optimum.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Pico-second laser materials interactions: mechanisms, material lifetime and performance optimization Ted Laurence(14-ERD-014)

Laser-induced damage with ps pulse widths straddles the transition from intrinsic, multiphoton ionization- and avalanche ionization-based ablation with fs pulses to defectdominated, thermal-based damage with ns pulses. We investigated the morphology and scaling of damage for commonly used silica and hafnia coatings as well as fused silica. Using carefully calibrated laser-induced damage experiments, in situ imaging, and high-resolution optical microscopy, atomic force microscopy, and scanning electron microscopy, we showed that defects play an important role in laser-induced damage for pulse durations as short as 1 ps. Three damage morphologies were observed: standard material ablation, ultra-high density pits, and isolated absorbers. For 10 ps and longer, the isolated absorbers limited the damage performance of the coating materials. We showed that damage resulting from the isolated absorbers grows dramatically with subsequent pulses for sufficient fluences. For hafnia coatings, we used electric field modeling and experiments to show that isolated absorbers near the surface were affected by the chemical environment (vacuum vs. air) for pulses as short as 10 ps. Coupled with the silica results, these results suggested that improvements in the performance in the 10 -60 ps range have not reached fundamental limits. These findings motivate new efforts, including a new SI LDRD in improving the laser-damage performance of multi-layer dielectric coatings. A damage test facility for ps pulses was developed and automated, and was used for testing production optics for ARC. The resulting software was transferred to other laser test facilities for fs pulses and multiple wavelengths with 30 ps pulses. Additionally, the LDRD supported the retention and promotion of an important staff scientist in high-resolution dynamic microscopy and laser-damage testing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A review on experimentally observed mechanical and microstructural characteristics of interfaces in multi-material laser powder bed fusion

Additive manufacturing (AM) is a revolutionary technology. One of the key AM categories, metal powder-based fusion processes, has many advantages compared to conventional methods for fabricating structural materials, such as permitting increased geometric complexity. While single material metal powder AM has advanced significantly in the past decade, multi-material AM is gradually attracting more attention owing to the recent breakthrough in multi-material feedstock delivery and the growing interest of fabricating functionally graded components. Multi-material AM offers an alternative route for applications that require location dependent material properties and high geometrical complexity. The AM community has invented several ways to achieve compositional gradients and discrete boundaries in two and three dimensions using mechanical spreading, nozzle-based, electrophotographic, and hybrid techniques. This article reviews the current state of laser powder bed fusion based multi-material AM of metals with focuses on the characteristics of the material interface as well as the properties and performance of the AM built functionally graded materials. We show the common challenges and issues related to material transitions, such as defects, segregation, phase separation, and the efficacy of some potential solutions including material and process optimizations. Additionally, this study evaluates the applicability and limitations of the existing testing standards and methods for measuring mechanical performance of functionally graded materials. Finally, we discuss mechanical testing development opportunities, which can help multi-material AM move towards higher technological maturity. In general, we find that the link between gradient microstructure and mechanical properties is not well understood or studied and suggest several mechanical tests that may better inform this knowledge gap.

42 ENGINEERING↗
DOE OSTI2018

Laser Material Processing Final Report CRADA No. TC-321-92

Current commercial cw flashlamp pumped solid-state laser systems employed in laser machining operate at multi-hundred watt to kilowatt levels and produce 30-100 times diffraction limited beam quality. Developing similar power lasers but with a beam quality 5-10 times better is an important advancement in the laser machining industry especially precision laser machining.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Laser Materials Processing Final Report CRADA No. TC-1526-98

This CRADA project was a joint effort between Lawrence Livermore National Laboratory (LLNL) and United Technologies Corporation (UTC)/Pratt & Whitney (P&W) to demonstrate process capability for drilling holes in turbine airfoils using LLNL-developed femtosecond laser machining technology. The basis for this development was the ability of femtosecond lasers to drill precision holes in variety of materials with little or no collateral damage. The ultimate objective was to develop a laser machine tool consisting of an extremely advanced femtosecond laser subsystem to be developed by LLNL on a best-effort basis and a drilling station for turbine blades and vanes to be developed by P&W. In addition, P&W was responsible for commercializing the system. The goal of the so called Advanced Laser Drilling (ALD) system was to drill specified complex hole-shapes in turbine blades and vanes with a high degree precision and repeatability and simultaneously capable of very high speed processing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Ultrafast Laser Material Damage Simulation—A New Look at an Old Problem

The chirped pulse amplification technique has enabled the generation of pulses of a few femtosecond duration with peak powers multi-Tera and Peta–Watt in the near infrared. Its implementation to realize even shorter pulse duration, higher energy, and higher repetition rate laser systems relies on overcoming the limitations imposed by laser damage of critical components. In particular, the laser damage of coatings in the amplifiers and in post-compression optics have become a bottleneck. The robustness of optical coatings is typically evaluated numerically through steady-state simulations of electric field enhancement in multilayer stacks. However, this approach cannot capture crucial characteristics of femtosecond laser induced damage (LID), as it only considers the geometry of the multilayer stack and the optical properties of the materials composing the stack. This approach neglects that in the interaction of an ultrashort pulse and the materials there is plasma generation and associated material modifications. Here, we present a numerical approach to estimate the LID threshold of dielectric multilayer coatings based on strong field electronic dynamics. In this dynamic scheme, the electric field propagation, photoionization, impact ionization, and electron heating are incorporated through a finite-difference time-domain algorithm. We applied our method to simulate the LID threshold of bulk fused silica, and of multilayer dielectric mirrors and gratings. The results are then compared with experimental measurements. The salient aspects of our model, such as the implementation of the Keldysh photoionization model, the impact ionization model, the electron collision model for ‘low’-temperature, dense plasma, and the LID threshold criterion for few-cycle pulses are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Advances in the Application of Lasers in Materials Science, Chapter 5, Insights into Laser-Materials Interaction Through Modeling on Atomic and Macroscopic Scales

Computer simulations and theoretical analysis of laser-materials interactions are playing an increasingly important role in the advancement of modern laser technologies and broadening the range of laser applications. In this chapter, we first provide an overview of the current understanding of the laser coupling and transient variation of optical properties in metals, semiconductors and dielectrics, with the focus on the practical implications on the energy deposition and distribution in the irradiated targets. The continuum-level modeling of the dynamic evolution of laser-induced stresses, nonequilibrium phase transformations, and material redistribution within the laser spot are then discussed, and the need for the physical insights into the mechanisms and kinetics of highly nonequilibrium processes triggered by the laser excitation is highlighted. The physical insights can be provided by atomistic modeling, and several examples are discussed where large-scale molecular dynamics simulations are used for investigation of the mechanisms of the generation of crystal defects (vacancies, interstitials, dislocations, and twin boundaries) and the material redistribution responsible for the formation of laser-induced periodic surface structures in the single-pulse ablative regime. The need for the integrated computational approach fully accounting for the strong coupling between processes occurring at different time- and length-scales is highlighted.

Shugaev, Maxim V.↗
DOE OSTI2023

Statistical Homogenization of Elastic and Fracture Properties of a Sample Selective Laser Melting Material

Selective laser melting (SLM) is an additive manufacturing technique commonly used in the rapid prototyping of components. The complexity of the SLM microstructure poses a unique challenge to deriving effective mechanical properties at different length scales. Representative volume elements (RVEs) are often used to homogenize the material properties of composites. Instead of RVEs, we use statistical volume elements (SVEs) to homogenize the elastic and fracture properties of the material. This relates the inherent variation of a material’s microstructure to the variation in its mechanical properties at different observation scales. The convergence to the RVE limit is examined from two perspectives: the stability of the mean value as the SVE size increases for the mean-based approach, and the tendency of the normalized variation in homogenized properties to zero as the SVE size increases for the variation-based approach. Fracture properties tend to make the RVE limit slower than do elastic properties from both perspectives. There are also differences between vertical (normal to printing plane) and horizontal (in-plane) properties. While the elastic properties tend to make the RVE limit faster for the horizontal direction, i.e., having a smaller variation and more stable mean value, the fracture properties exhibit the opposite effect. We attributed these differences to the geometry of the melt pools.

36 MATERIALS SCIENCE↗