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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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16 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Adhesion Testing of Direct-Write Printed Ink on Metallic Structural Components

The successful adoption of additive manufacturing for the rapid prototyping of direct-write printed electronics requires the establishment of quantifiable metrics that can interrogate device performance. One measure of performance is the adhesion strength between the substrate and printed film interface, which is critical since the strength of this interface can dictate the accuracy and reliability of the printed device. In this work, a non-contact laser-induced spallation technique was used to quantify the adhesion of silver printed films on aluminum alloy substrates. The laser-based method was compared to a standardized pull-off adhesion test, which provided baseline measurements of adhesion strength. The sintering conditions were shown to play an important role in the film-substrate adhesion strength, as well as the cohesion and ductility of the film itself. The methods and results described in this work support the establishment of process control steps that are necessary for quickly verifying the reliability of printed devices prior to their deployment in critical experiments.

Adhesion test↗
DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties).To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗
NASA NTRS1986

Identification of cosmogenic argon components in Allende by laser microprobe

New techniques are presented for using a laser microprobe to determine the spallation argon systematics of calcium-aluminum inclusions. The Ar-38(s) amounts determined for melilite and anorthite in a coarse-grained inclusion from Allende are 2.9 x 10 to the -8th and 1.3 x 10 to the -8th cc/g, respectively. The ratio of the amounts is consistent with the calcium contents of these two minerals. The Ar-38(s) amount determined for a fine-grained inclusion from Allende is 1.1 x 10 to the -8th cc/g. Calcium and potassium amounts were determined from irradiated samples of the same inclusions so that production of Ar-38 from calcium during the cosmic ray exposure of Allende could be determined for these samples. The production observed was 12.4 + or - 2.1 x 10 to the -8th cc STP Ar-38/g Ca for the coarse-grained inclusion and 9.9 + or - 2.4 cc STP Ar-38/g Ca for the fine-grained inclusion. No evidence of unusual exposure was observed in the two inclusions studied.

Kirschbaum, C.↗
DOE OSTI2025

Laser beam pointing stabilization using analog position-sensitive diodes

Laser wire scanners have been used for ion beam profile and emittance measurements at the Spallation Neutron Source linear accelerator. Due to propagation distances exceeding 100 m, reliable measurements require laser beam stabilization, previously accomplished with a feedback control loop using a digital camera as a position sensor [Hardin et al., Opt. Express 19, 2874 (2011)]. Here, this paper presents an upgraded pointing stabilization system utilizing analog position-sensitive diodes (PSDs) as the position detector, optimized with an optical diffuser. The new system significantly surpasses the previous system by offering an order-of-magnitude improvement in radiation tolerance and a bandwidth limited only by the burst repetition rate of the laser beam. Operating with a 60-Hz burst mode laser, the new system effectively suppresses laser beam drifts up to 30 Hz, compared to the previous system’s 4 Hz limit. In addition, the amplitude of spectral components below 0.1 Hz was reduced by a factor of more than 100, which is over seven times greater than was achieved by the previous system.

Data acquisition↗
NASA NTRS1972

Gas analysis of Apollo 12, 14, and 15 samples by laser-probe mass spectrometry

Solar wind gases, cosmogenic gases from high energy spallation reactions from soxmic rays, and radiogenic gases from decay of radioactive potassium and from uranium and thorium isotopes were analyzed in lunar materials. Details are presented on two aspects of the studies: (1) The spatial distribution of Ar-40/Ar-38 ages in lunar breccia 14301 was determined. The ages of clasts within this breccia are 3.68 + or - 0.09 and 2.9 + or - 0.3 x 10 to the 9th power years. Parentless radiogenic Ar-40 exists within the fine-grained matrix. (2) The distribution of helium, neon, and argon isotopes within Apollo 15 samples results primarily from fractionated solar wind gases, accompanied by small quantities of cosmogenic gases. Comparison of this Apollo 15 data with Kapoeta and Fayetteville meteorite and Apollo 12 and 14 data indicates that solar wind implantation followed by fractionation of the gases was primarily responsible for incorporation of original gas phase within solid bodies of the solar system.

Imegrue, G. H.↗
DOE OSTI2026

Phase Drifts and Signal Dispersion in Coaxial Cables

Phase reference distribution is a critical challenge in modern linear particle accelerators, such as European Spallation Source (ESS), European X-ray Free Electron Laser (E-XFEL), or Proton Improvement Plan II (PIP-II). Similar issues may also arise in other RF systems that need to synchronize many independent circuits. Achieving low phase drift of the reference signal requires careful selection of cables and their environmental operating conditions. Due to the limited data provided by cable manufacturers, it is necessary to characterize the cable performance. This article investigates the phase drifts in coaxial cables and presents a dedicated measurement methodology. The dispersion characteristics of the cables are also examined. The measurement results of various coaxial cables are presented, along with conclusions and practical guidelines for designers of phase reference distribution lines.

coaxial cables↗
NASA NTRS1982

Spallation of the Galileo probe heat shield

The Galileo probe heat shield will encounter severe radiative and convective heating during entry into Jupiter's atmosphere. The shield is made of two different carbon phenolic composites; one is chopped-molded, and the other is tape-wrapped, both of which tend to spall under intense heating conditions. To characterize this phenomenon, an experimental program, using a gasdynamic laser, was initiated. Tests were performed at a variety of radiation intensities, and both the total and spallation mass-loss rates were measured and correlated with intensity. These correlations were then applied to calculated flight heating conditions for two model atmospheres. Entry of a 310-kg probe into the nominal atmosphere would result in a spallation mass loss of 6.3 kg, or 7.4% of the expected thermochemical mass loss. Similarly, entry of that probe into the cool-dense atmosphere would result in 11.9 kg of spallation, or about 10% of the expected thermochemical mass loss.

Lundell, J. H.↗
DOE OSTI2025

Dynamic response of 17-4 stainless steel as a function of manufacturing method and heat treatment

We present a series of plate-impact experiments on 17-4 stainless steel to study the effect of manufacturing method and heat treatment on the Hugoniot elastic limit (HEL), Hugoniot, phase transformation stress, and spallation strength. Two traditional manufacturing methods were considered, wrought processing and casting, as well as two additive manufacturing methods, laser powder-bed fusion (LPBF) and wire-fed electron beam (EBAM). For both LPBF and EBAM 17-4 stainless steel variants, two billets were printed, enabling the application of two unique heat treatments. The HEL stress depended heavily on the thermal history, with the HEL increasing after the formation of Cu-rich precipitates via heat treatment. The Hugoniot response both below and above the phase transition was unaffected by the manufacturing method or heat treatment. The phase transition stress depended heavily on the thermal history, with its variation being attributed to the presence of various microstructural features. This is supported by a marked increase in the phase transition stress after precipitation hardening. These results suggest that the notion of the phase transition stress being dictated by bulk composition is an oversimplification and the stress fields generated by the meso-scale structure are a dominant force. The spallation strength was lower in the cast material compared to all other 17-4 stainless steel variants due to the presence of brittle δ-ferrite inclusions. Additionally, a drop in the tensile strain-rate was observed in the spallation response above the phase transition stress, which was hypothesized to stem from the kinetics of the reversion to the low-pressure phase during spall.

Compressive stress↗
DOE OSTI2025

Defect And Damage Characterization Of Additively Manufactured Titanium Alloy Ti-5553 Using Traditional Computed Tomography Volume Segmentation And Machine Learning Algorithms

The mechanical response of a component is affected by defects, such as porosity, arising from the laser powder bed fusion (LPBF) fabrication process. Thus, it is important to develop accurate and efficient inspection methods for identifying porosity. In this work, porosity identified in an X-ray computed tomography (XCT) volume of a Ti-5553 coupon was compared to pores identified in a serial sectioned volume that represented the ground truth. The porosity of the XCT scan was identified using contrast-based, ISO-based, and machine learning (ML) methods for segmentation. Large inherent porosity was easy to identify, but the ISO thresholding still struggled due to the intensity gradient resulting from both the beam hardening in XCT and the uneven lighting of the serial sectioning panels. Further, the results show that ML-based methods were better suited for identifying small pores and reducing the amount of false positives. Additionally, high strain-rate impact testing was done on some of the XCT samples as well as post-mortem XCT inspection, and the same suite of segmentation and quantification tools were used to identify the large spallation cavities. The comparison of porosity pre- and post-mortem provides insight on the influence of the LPBF porosity on the formation of spall cavities.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Modeling the Interaction of Laser-Produced Proton Beams with Matter

A major goal of this project is to significantly increase our understanding of isochoric heating of matter using laser produced proton beams, and the associated high energy density (HED) and warm dense matter (WDM) regimes generated. This will benefit research fields such as planetary science, fusion energy, plasma physics, and material science. For example, it will enhance our understanding of WDM properties of iron and silica under conditions encountered in planetary interiors and diagnostic components in fusion devices exposed to high fluxes of energetic plasma ions. The project is motivated by recent experiments that irradiated Si targets with proton beams generated by the 20 TW-laser at the SLAC MEC end-station. The HED/WDM states are probed using the 50 fs hard X-rays available in the 3rd harmonic of the LCLS. As part of this project, results from the phase contrast X-ray imaging, which shows the generation of compression waves that produces rear surface spallation, are compared with results from the 3D multi-physics multi- material code, PISALE, that combines Arbitrary Lagrangian-Eulerian (ALE) hydrodynamics with Adaptive Mesh Refinement (AMR). This comparison required modifications to several physics models in the PISALE (Pacific Island Structured-AMR with ALE) code. An important aspect of this project is the continued training of graduate students in HED physics and in conducting complex multiphysics simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1990

Cosmogenic neon from individual grains of CM meteorites - Extremely long pre-compaction exposure histories or an enhanced early particle flux

This paper presents the results on cosmogenic Ne extracted from individual meteoritic grains by a laser extraction system which used, at different times, two CW lasers: an Ar-ion laser and an Nd:YAG laser, with 20 and 70 W of deliverable power, respectively. Chemical etching was used to select grains exposed to solar flare VH particles. Results show that most of the grains with solar flare VH tracks (but not those which did not exhibit such tracks) contain spallation-produed Ne in significant excess of that due to the nominal cosmic-ray exposure, providing evidence for extensive energetic particle exposure during the precompaction era.

Hohenberg, Charles M.↗
NASA NTRS2014

Neutron Imaging for Selective Laser Melting Inconel Hardware with Internal Passages

Additive Manufacturing is showing great promise for the development of new innovative designs and large potential life cycle cost reduction for the Aerospace Industry. However, more development work is required to move this technology into space flight hardware production. With selective laser melting (SLM), hardware that once consisted of multiple, carefully machined and inspected pieces, joined together can be made in one part. However standard inspection techniques cannot be used to verify that the internal passages are within dimensional tolerances or surface finish requirements. NASA/MSFC traveled to Oak Ridge National Lab's (ORNL) Spallation Neutron Source to perform some non-destructive, proof of concept imaging measurements to assess the capabilities to understand internal dimensional tolerances and internal passages surface roughness. This presentation will describe 1) the goals of this proof of concept testing, 2) the lessons learned when designing and building these Inconel 718 test specimens to minimize beam time, 3) the neutron imaging test setup and test procedure to get the images, 4) the initial results in images, volume and a video, 4) the assessment of using this imaging technique to gather real data for designing internal flow passages in SLM manufacturing aerospace hardware, and lastly 5) how proper cleaning of the internal passages is critically important. In summary, the initial results are very promising and continued development of a technique to assist in SLM development for aerospace components is desired by both NASA and ORNL. A plan forward that benefits both ORNL and NASA will also be presented, based on the promising initial results. The initial images and volume reconstruction showed that clean, clear images of the internal passages geometry are obtainable. These clear images of the internal passages of simple geometries will be compared to the build model to determine any differences. One surprising result was that a new cleaning process was used on these simply geometric specimens that resulted in what appears to be very smooth internal surfaces, when compared to other aerospace hardware cleaning methods.

Tramel, Terri L.↗
DOE OSTI2024

Exploring uranium oxidation in glue vapor to help avoid catastrophic slivers on NIF targets

Depleted uranium (DU) hohlraums are utilized for indirect drive fusion experiments at Lawrence Livermore National Laboratory. The production process for DU hohlraums is intricate, involving complex sputtering, machining, and leaching techniques. Achieving low-stress and defect-free hohlraums presents significant challenges. Recent failures have revealed that some uranium flakes, known as slivers, detach from the diagnostic windows and fall onto the capsule. These catastrophic failures were observed only after target assembly, leading to the hypothesis that oxidation of the DU by glue vapor might be the cause. A study investigating the impact of glue vapor on DU hohlraums found that spallation occurred in three out of seven sample hohlraums after three weeks. The slivers observed in these samples were consistent with those seen in assembled targets. This marks the first experimental reproduction of such catastrophic slivering failures. Consequently, future studies can now focus on sliver mitigation and the precise diagnosis of the failure mode.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2015

Radiant Heating Tests on Meteoritic Material

A new effort geared toward modeling the physics of meteor entry and break-up is underway at NASA Ames Research Center. This is part of a broader interdisciplinary effort on providing physics-based risk assessment models for potentially hazardous objects. As part of the entry modeling task we are seeking to improve our understanding of, among other things, the ablation of meteoric material during high speed entry into earths atmosphere. Meteoroid entry differs greatly in some key respects from spacecraft entry modeling. First, the aerothermal environment at these high velocities (18 km/s) is dominated by radiation. Second, meteoroids less than, say, 50m in size, will likely lose a significant portion of their mass during the high-speed atmospheric entry process due to vaporization as well as melting and spallation. The mass of the object, in turn, directly affects the amount of energy deposited in the atmosphere, and therefore the amount of damage done. Thus it is important for us to understand and be able to model this process in greater detail in order to assess the hazard posed by these objects.In this presentation, we first give an overview of the simple ablation models that are typically used in meteor entry calculations. Additionally, we will present a new model which utilizes a similar approach to what is typically done for spacecraft TPS response modeling. This uses an equilibrium assumption near the surface to compute the ablation rate, as is done in heritage material response codes. Next we describe the radiant heating experiment which uses a high-powered laser to emulate the radiation dominated heating environment experienced by meteoroids during atmospheric entry. The facility the Laser Hardened Material Evaluation Laboratory (LHMEL) permits us to expose samples of meteoritic material to heating rates in excess of 100kW/sq.cm. An overview of the experimental set-up and test plan for the initial exploratory campaign at this facility will be given. Then we present both qualitative and quantitative results from this initial test series. Comparisons between predicted and measured ablation rates suggest that there may be significant blockage of the incident beam by the ablation plume. Furthermore, melt is shown to be a significant ablation mechanics, even at high heating rates (16 kW/sq.cm). Finally, comparisons between the phenomenology of the ablation of terrestrial rocks namely, basalt -- to that of meteorites show very different behavior. This is shown to likely be due in part to the effect of composition on the melt viscosity.

Stern, Eric↗
NASA NTRS1997

Extraterrestrial Helium (He@C60) Trapped in Fullerenes in the Sudbury Impact Structure

Fullerenes (C60 and C70) have recently been identified in a shock-produced breccia (Onaping Formation) associated with the 1.85-Ga Sudbury Impact Crater. The presence of parts-per-million levels of fullerenes in this impact structure raises interesting questions about the processes that led to the formation of fullerenes and the potential for delivery of intact organic material to the Earth by a large bolide (e.g., asteroid or comet). Two possible scenarios for the presence of fullerenes in the Sudbury impact deposits are that (1) fullerenes are synthesized within the impact plume from the C contained in the bolide; or (2) fullerenes are already present in the bolide and survived the impact event. The correlation of C and trapped noble gas atoms in meteorites is well established. Primitive meteorites contain several trapped noble gas components that have anomalous isotopic compositions, some of which may have a presolar origin. Several C-bearing phases, including SiC, graphite, and diamond, have been recognized as carriers of trapped noble gases. It has also been suggested that fullerenes (C60 and C70) might be a carrier of noble gas components in carbonaceous chondrites. Recently, fullerenes have been detected in separate samples in the Allende meteorite. Carbon-60 is large enough to enclose the noble gases He, Ne, Ar, Kr, and Xe, but it is too small to contain diatomic gases such as N2 or triatomic gases such as CO2. Recent experimental work has demonstrated that noble gases of a specific isotopic composition can be introduced into synthetic fullerenes at high temperatures and pressures; these encapsulated gases can then be released by the breaking of one or more C bonds during step-heating under vacuum. These thermal-release patterns for He encapsulated within the C60 molecule (He@C60) are similar to the patterns for acid residues of carbonaceous chondrites, suggesting that fullerenes could be an additional carrier of trapped noble gases in acid residues of meteorites. Analysis and Results: In order to characterize the noble gas compositions of the Sudbury fullerenes, we undertook a systematic study of acid-resistant residues throughout the C-rich layer (Black member) of the Onaping Formation. Samples were demineralized and extracted using standard techniques. The Onaping extracts were analyzed using several techniques, including UV-Vis adsorption, electro spray mass spectrometry, and laser desorption (linear and reflectron) time-of-flight (TOF) mass spectrometry (LDMS). The Sudbury fullerenes were then separated and purified using HPLC coupled with a photo diode array detector. The HPLC extracts containing the purified fullerenes were loaded into a metal tube furnace within a glove box under a N atmosphere in preparation for noble gas analyses. The 3-He and 4-He content of the fullerene extracts was measured using previously reported standard techniques . Discussion: Fullerenes (C60 and C70) in the Sudbury Impact Structure have been found to contain trapped He with a 3-He/4-He ratio greater than 5 x 10(exp -4). The 3-He/4-He ratio exceeds the accepted solar value by more than 30% and is more than 10x higher than the maximum reported mantle value. Terrestrial nuclear reactions or cosmic-my bombardment are not sufficient to generate such a high ratio. The 3-He/4-He ratios in the Sudbury fullerenes are similar to those determined for interplanetary dust particles. The greater-than-solar ratios of 3-He/4-He in the Sudbury fullerenes may indicate a presolar origin, although alternative mechanisms occurring in the ISM to explain these high ratios (e.g., spallation reactions, selective He implantation, etc.) cannot be entirely ruled out. We are currently attempting to isolate enough fullerene material to measure anomalous Ne (or Kr or Xe) contained within the C60 (e.g., the "pure" 22-Ne component) and thus determine whether the Sudbury fullerenes are indeed presolar in origin.

Becker, L.↗