Charles D. Boley

Calculation of laser absorption by metal powders in additive manufacturing

We have calculated the absorption of laser light by a powder of metal spheres, typical of the powder employed in laser powder-bed fusion additive manufacturing. Using ray-trace simulations, we show that the absorption is significantly larger than its value for normal incidence on a flat surface, due to multiple scattering. We investigate the dependence of absorption on powder content (material, size distribution, and geometry) and on beam size.

Spatial filter pinhole development for the National Ignition Facility

We present results from a major experimental effort to understand the behavior of spatial filter pinholes and to identify and demonstrate a pinhole that will meet the requirements of the National Ignition Facility (NIF). We find that pinhole performance depends significantly on geometry and material. Cone pinholes are found to stay open longer and to cause less backreflection than pinholes of more conventional geometry. We show that a +/-150-microrad stainless-steel cone pinhole will pass a full-energy NIF ignition pulse with required margins for misalignment and for smoothing by spectral dispersion. On the basis of a model fitted to experimental results, a +/-125-microrad stainless-steel cone pinhole is also projected to meet these requirements.

Interaction of a high-power laser beam with metal sheets

Experiments with a high-power laser beam directed onto thin aluminum sheets, with a large spot size, demonstrate that airflow produces a strong enhancement of the interaction. The enhancement is explained in terms of aerodynamic effects. As laser heating softens the material, the airflow-induced pressure difference between front and rear faces causes the metal to bulge into the beam. The resulting shear stresses rupture the material and remove it at temperatures well below the melting point. The material heating is shown to conform to an elementary model. We present an analytic model of elastic bulging. Scaling with respect to spot size, wind speed, and material parameters is determined.

Modeling of plasma behavior in a plasma electrode Pockels cell

We present three interrelated models of plasma behavior in a plasma electrode Pockels cell (PEPC). In a PEPC, plasma discharges are formed on both sides of a thin, large-aperture electro-optic crystal (typically KDP). The plasmas act as optically transparent, highly conductive electrodes, allowing uniform application of a longitudinal field to induce birefringence in the crystal. First, we model the plasma in the thin direction, perpendicular to the crystal, via a one-dimensional fluid model. This yields the electron temperature and the density and velocity profiles in this direction as functions of the neutral pressure, the plasma channel width, and the discharge current density. Next, me model the temporal response of the crystal to the charging process, combining a circuit model with a model of the sheath which forms near the crystal boundary. This model gives the time-dependent voltage drop across the sheath as a function of electron density at the sheath entrance. Finally, we develop a two dimensional MHD model of the planar plasma, in order to calculate the response of the plasma to magnetic fields. We show how the plasma uniformity is affected by the design of the current return, by the longitudinal field from the cathode magnetron, and by fields from other sources. This model also gives the plasma sensitivity to the boundary potential at which the top and bottom of the discharge are held. We validate these models by showing how they explain observations in three large Pockels cells built at Lawrence Livermore National Laboratory.

Modeling of laser interactions with composite materials

We develop models of laser interactions with composite materials consisting of fibers embedded within a matrix. A ray-trace model is shown to determine the absorptivity, absorption depth, and optical power enhancement within the material, as well as the angular distribution of the reflected light. We also develop a macroscopic model, which provides physical insight and overall results. We show that the parameters in this model can be determined from the ray trace model.

Metal powder absorptivity: modeling and experiment

We present results of numerical modeling and direct calorimetric measurements of the powder absorptivity for a number of metals. The modeling results generally correlate well with experiment. We show that the powder absorptivity is determined, to a great extent, by the absorptivity of a flat surface at normal incidence. Our results allow the prediction of the powder absorptivity from normal flat-surface absorptivity measurements.

Beam characteristics of a large-bore copper laser with radiatively cooled plasma

In a large-bore copper vapor laser (CVL), excessive gas heating at the axial region of the discharge lowers its efficiency by thermally populating the metastable lower laser levels. The associated lower gas density also lengthens the discharge field- diffusion time, leading to weaker axial pumping and undesired beam characteristics. A novel approach to circumvent this obstacle has been developed by cooling the plasma radiatively via a series of segmented metal plates (septa) placed vertically along the length of the tube. This improved tube design significantly lowers the average gas temperature and shortens the radial delay. A 27% increase in laser power was observed with the addition of septa. We have characterized the beam intensity profile, spatial and temporal pulse variation, and beam polarization through extensive laboratory measurements. A detailed computational model of the laser has been used to characterize and interpret the laboratory results.

Development of a Process Model for CO(2) Laser Mitigation of Damage Growth in Fused Silica

A numerical model of CO2 laser mitigation of damage growth in fused silica has been constructed that accounts for laser energy absorption, heat conduction, radiation transport, evaporation of fused silica and thermally induced stresses. This model will be used to understand scaling issues and effects of pulse and beam shapes on material removal, temperatures reached and stresses generated. Initial calculations show good agreement of simulated and measured material removal. The model has also been applied to LG-770 glass as a prototype red blocker material.

High-power copper vapour lasers and applications

Expanded applications of copper vapor lasers has prompted increased demand for higher power and better beam quality. This paper reports recent progress in laser power scaling, MOPA operation, beam quality improvement, and applications in precision laser machining. Issues such as gas heating, radial delay, discharge instability, and window heating will also be discussed.

Spatial filter issues

Beamlet measurements show that cone pinholes outperform other types tested with regard to both closure and back reflections. A +/- 150 (mu) rad stainless steel cone remained open for a 15.5 kJ, 10:1 contrast shaped pulse with +/- 7.5 (mu) rad of SSD divergence, which more than meets the requirements for a NIF ignition pulse. Measurements also showed the maximum tolerable pressures in the NIF spatial filters to be a few milliTorr, leading to recommendations of 0.1 nd 0.6 mTorr for the NIF transport and cavity spatial filters, respectively.