A novel approach to the deposition of Co-Mo-Cr-Si coating on Haynes 282 by laser fusion and laser remelting
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Materials Science↗
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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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Suppression of the Biermann Battery and Stabilization of the Thermomagnetic Instability in Laser Fusion Conditions
Magnetic field generated by the Biermann battery is thought to be one of the principal mechanisms behind the inhibition of heat flow in laser-plasma interactions, and is predicted to grow exponentially in some contexts due to the thermomagnetic instability [Tidman and Shanny, Phys. Fluids 17, 1207 (1974)]. In contrast to these predictions, however, here we have conducted Vlasov-Fokker-Planck simulations of magnetic field dynamics under a range of classically unstable laser-fusion conditions, and find field generation to be strongly suppressed, preventing magnetization of the transport, and stabilizing instability. By deriving new scaling laws, we show that this stabilization is a consequence of (i) heavy suppression of the Biermann battery under nonlocal conditions; (ii) rapid convection of magnetic field by the heat flow; and (iii) comparatively short field length scales. Our results indicate that classical models substantially overestimate the importance of magnetic fields generated by the Biermann battery, and the susceptibility of laser-fusion plasmas to the thermomagnetic instability.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Correlations of Additive Manufacturing Model-Based Process Metrics With Spatter-Induced Porosity in the Powder Bed Fusion-Laser Beam/Metallic Process
Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Qualifying materials for components in critical applications requires a thorough understanding of pertinent processing-microstructure-property relationships. Porosity defects have a strong adverse effect on the mechanical properties of a material. The morphology of porosity defects created by lack of fusion in PBF-LB/M often exhibit high aspect ratios that can act as stress concentrators and become crack initiation sites. The occurrence of spatter induced porosity is studied using synchronized AM model-based process metrics and porosity measured by high-resolution X-ray computed tomography. A novel AM process metric is introduced to quantify the relative exposure to spatter ejecta impacts and incorporation throughout the sequence of the PBF-LB/M process. Further characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated statistically with the spatter ejecta impact field of the PBF-LB/M process. Both keyhole and lack of fusion porosity can be predicted by the spatter exposure process metric, which can be exploited to control the fusion sequence.
Additive Manufacturing↗
Correlations Between Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing
Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M)additive manufacturing process are the result of a multitude of weld passes conducted sequentially. Qualifying components for aerospace applications requires a thorough understanding of the process-structure-properties relationships. Porosity defects are known to have a strong adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. The results show that lack of fusion porosity is statistically correlated with unremoved welding spatter ejecta of the PBF-LB/M process and process metrics related to the hatching strategy.
Qualification↗
Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification
The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.
Laser Powder Bed Fusion↗
Direct-drive laser fusion: status, plans and future
Laser-direct drive (LDD), along with laser indirect (X-ray) drive (LID) and magnetic drive with pulsed power, is one of the three viable inertial confinement fusion approaches to achieving fusion ignition and gain in the laboratory. The LDD programme is primarily being executed at both the Omega Laser Facility at the Laboratory for Laser Energetics and at the National Ignition Facility (NIF) at Lawrence Livermore National Laboratory. LDD research at Omega includes cryogenic implosions, fundamental physics including material properties, hydrodynamics and laser–plasma interaction physics. LDD research on the NIF is focused on energy coupling and laser–plasma interactions physics at ignition-scale plasmas. Limited implosions on the NIF in the ‘polar-drive’ configuration, where the irradiation geometry is configured for LID, are also a feature of LDD research. The ability to conduct research over a large range of energy, power and scale size using both Omega and the NIF is a major positive aspect of LDD research that reduces the risk in scaling from OMEGA to megajoule-class lasers. Furthermore, the paper will summarize the present status of LDD research and plans for the future with the goal of ultimately achieving a burning plasma in the laboratory.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
On-target uniformity of the OMEGA 60-beam inertial confinement fusion laser
Successful direct-drive inertial confinement fusion (ICF) experiments require excellent on-target laser 9 irradiance uniformity maintained over the duration of the pulse. Achieving this symmetry relies on maintaining an 10 energy, power, and fluence balance among all beams in a multibeam laser system. As a result of the improvements 11 described in this paper, the OMEGA 60-beam laser performance has been assessed at approximately 2% on-target 12 irradiance nonuniformity using an updated performance assessment metric that accounts for the laser diagnostic noise 13 floor. The performance is measurement-limited, prompting the need for an improved diagnostic suite. This manuscript 14 provides a comprehensive first-order assessment of extant status of on-target energy, power, and fluence uniformity 15 and explores avenues for improvements.
Diagnostics↗
Principal factors in performance of indirect-drive laser fusion experiments
Progress in inertial confinement fusion depends on the accurate interpretation of experiments that are complex and difficult to explain with simulations. Results could depend on small changes in the laser pulse or target or physics that are not fully understood or characterized. In this paper we discuss an x-ray-driven platform with fewer sources of degradation, and find the fusion yield can be described as a physically motivated function of laser energy, target scale, and implosion symmetry. Furthermore, this platform and analysis could enable a more experimental approach to the study and optimization of implosion physics.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Status and prospects for inertial fusion energy via lasers
Fusion energy is the ultimate clean and limitless energy source, but its development requires overcoming many scientific and technological challenges. For the first time in the 60-year long history of fusion research, ignition and target gain above unity (G>1) were demonstrated in the laboratory at the National Ignition Facility at the Lawrence Livermore National Laboratory in 2022. Turning laser fusion into an energy source requires that the results from single shot experiments be replicated at much higher repetition rates of many shots per second to produce high average power at relatively low cost. Furthermore, this requires the development of new laser technologies, mass production of suitable targets, accurate injection and tracking systems and new materials for the reactor chamber components and final optics. Ultra broadband and deep UV light are laser advances that can dramatically improve the laser energy coupling to the target thereby reducing the laser energy and power requirements.
Fusion energy↗
Optimization of Backscatter and Symmetry for Laser Fusion Experiments Using Multiple Tunable Wavelengths
A new additional wavelength-tuning capability has been implemented on the National Ignition Facility (NIF) laser allowing for unprecedented control of crossed-beam energy transfer (CBET) between all groups of beams for better performance of indirect-drive inertial confinement fusion (ICF) ignition experiments. In particular, this advance allows for negation and reversal of flow-induced CBET and the rebalancing of the intensity of different groups of beams within an indirect-drive (ICF) hohlraum. The experiments conducted at the NIF using a 1.1 MJ laser pulse with peak power of 390 TW demonstrate this high level of control through measurements of the precise changes to stimulated Brillouin scattering, typically driven by flow-induced CBET at the end of the pulse. Additionally, this new capability is shown to be able to predictably control gold-wall plasma expansion in the target driven by early-time flow-induced CBET. Estimates of early-time CBET from the wall expansion are shown to be consistent with simulation expectations. This new additional capability to control symmetry and backscatter expands the design space of current experiments and provides extra margin for increased laser energy in near-future experiments.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Applications of a Rayleigh-Taylor model to direct-drive laser fusion
Here, this paper presents a simple physics-based model for the interpretation of key metrics in laser direct drive. The only input parameters required are target scale, in-flight aspect ratio, and beam-to-target radius, and the importance of each has been quantified with a tailored set of cryogenic implosion experiments. These analyses lead to compact and accurate predictions of the fusion yield and areal density as a function of hydrodynamic stability, and suggest new ways to take advantage of direct drive. To provide examples, we will discuss how the inferred mix width behaves relative to theory, then show how it could be exploited to perform a direct drive implosion with a Lawson metric or Χ no α of 0.24 ± 0.02—using a novel parameter space at high velocities and beam radii on the OMEGA laser—that projects to ignition at a laser energy ≤2.0 MJ.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Comparison of chamber beam geometry robustness to mispointing, imbalance and target offset for direct-drive laser fusion facilities
This study focuses on the optimization of beam chamber geometry designs for future direct-drive laser facilities. It provides a review of leading target chamber geometries, with a particular emphasis on random errors. Through comprehensive solid-sphere illuminations and analysis, we identify an optimized beam geometry design, highlighting its robustness and performance under realistic experimental conditions. Three major sources of random errors are evaluated, closely linked to experimental evaluations at OMEGA. The findings underscore the importance of optimizing the irradiation system alongside beam pattern considerations to enhance the efficiency and reliability of inertial confinement fusion experiments. We conclude that for a desired illumination uniformity of 1% in the presence of system errors, the split icosahedron design is the most robust. However, for a 0.3% uniformity goal, the charged-particle, icosahedron, and t-sphere methods exhibit similar performance.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Principal factors in performance of indirect-drive laser fusion experiments
Progress in inertial confinement fusion depends on the accurate interpretation of experiments that are complex and difficult to explain with simulations. Results could depend on small changes in the laser pulse or target or physics that are not fully understood or characterized. In this paper we discuss an x-ray-driven platform [K. Baker et al., Phys. Rev. Lett. 121, 135001 (2018)] with fewer sources of degradation, and find the fusion yield can be described as a physically motivated function of laser energy, target scale, and implosion symmetry. This platform and analysis could enable a more experimental approach to the study and optimization of implosion physics.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Limits of dispersoid size and number density in oxide dispersion strengthened alloys fabricated with powder bed fusion-laser beam
Not Available
36 MATERIALS SCIENCE↗
Propagation of Input Uncertainties in Numerical Simulations of Laser Powder Bed Fusion
Laser powder bed fusion has the potential of redefining state-of-the-art processing and production methods, but defect formation and inconsistent build quality have limited the implementation of this process. Numerical models are widely used to study this process and predict the formation of these defects. Presently, the uncertainties of model input parameters and thermophysical properties used by these numerical simulations have not been investigated. In the present study, the uncertainty in these input parameters and material properties are quantified for laser powder bed fusion, with and without a simulated powder bed, to determine their influence on the predictive accuracy of an experimentally validated numerical model. Accounting for all possible sources of uncertainty quickly becomes computationally expensive on account of the curse of dimensionality. Uncertainty in laser absorption, solid, and liquid specific heat of the metal were found to have the largest effect on model prediction reliability with or without the use of a powder bed. Results also illustrate that accounting for these three uncertain parameters still captures the majority of model prediction uncertainty. Furthermore, the methodology of this study may be used to understand the uncertainty in as-built microstructure through propagation to microstructure prediction models, or applied under processing conditions where high Péclet numbers are observed and the thermal convection and fluid flow within the molten pool are substantial.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
In-Situ Characterization of Pore Formation Dynamics in Pulsed Wave Laser Powder Bed Fusion
Laser powder bed fusion (LPBF) is an additive manufacturing technology with the capability of printing complex metal parts directly from digital models. Between two available emission modes employed in LPBF printing systems, pulsed wave (PW) emission provides more control over the heat input compared to continuous wave (CW) emission, which is highly beneficial for printing parts with intricate features. However, parts printed with pulsed wave LPBF (PW-LPBF) commonly contain pores, which degrade their mechanical properties. In this study, we reveal pore formation mechanisms during PW-LPBF in real time by using an in-situ high-speed synchrotron x-ray imaging technique. We found that vapor depression collapse proceeds when the laser irradiation stops within one pulse, resulting in occasional pore formation during PW-LPBF. We also revealed that the melt ejection and rapid melt pool solidification during pulsed-wave laser melting resulted in cavity formation and subsequent formation of a pore pattern in the melted track. The pore formation dynamics revealed here may provide guidance on developing pore elimination approaches.
36 MATERIALS SCIENCE↗
Tracking of Marangoni driven motion during laser powder bed fusion
Laser Powder Bed Fusion (LPBF) can be used to create Functionally Graded Materials (FGMs) by selectively distributing property augmenting particles throughout the build matrix. With this method parts can be created with nonhomogeneous properties tuned to spatially varied, pre-determined design constraints. To unlock this capability, the fluid motion that occurs in the molten liquid phase must be thoroughly understood. More importantly, the actual tracking of motion during the LPBF process is needed. Further, a numerical model of heat transfer and fluid flow in LPBF process was created. Using results from the model the motion of particles starting at many different locations was tracked. The average change in position for these particles based on starting location was calculated. The effects of non-dimensional parameters on melt pool size were examined. These results were validated experimentally and compared to what is available in the literature.
42 ENGINEERING↗
Developing ductile and isotropic Ti alloy with tailored composition for laser powder bed fusion
Laser powder bed fusion (LPBF) is an advanced technology to create metallic components with complex geometry. Ti-6Al-4V (Ti64) is one of the most frequently used materials for LPBF. The intrinsic high cooling rates and ultra-high directional thermal gradient of melt, however, lead to a hierarchical structure composed of fine martensitic alpha' within columnar prior-beta grains in LPBF Ti64. This microstructure results in poor ductility and strong mechanical anisotropy in as-built Ti64 components, which largely limit their applications. Here, we report that the above shortcomings can be overcome by tailoring the alloy composition. Specifically, by reducing the aluminum content from 6 wt% to 4 wt%, the resultant LPBF Ti-4Al-4V (Ti44) alloy exhibits substantially improved ductility and mechanical isotropy. These improvements are attributed to grain refinement during solidification and the activation of multiple slip modes and twinning in the as-built material during deformation. This work offers a simple strategy to design new titanium alloys for LPBF with significantly improved ductility and isotropy.
36 MATERIALS SCIENCE↗