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Because OFDR-based fiber interrogation systems rely upon interferometry between sensors with respect to a unique reference length, the excitation source (laser) must lase at a single longitudinal mode (SLM). If the excitation source contains multiple modes, the resulting beat frequency becomes a super-position of the multiple frequencies caused by the modes; as a result, the sensor cannot be accurately defined in the Fourier domain. For OFDR systems with high sensing ranges, a continuous wavelength tunable laser must be used to accommodate the resonant wavelength shift of the fiber sensors due to environmental changes. External cavity lasers (ECLs) have been used due to their narrow linewidth and ability to lase at a SLM with no mode-hopping between steps. However, the mechanical complexity associated with tuning, susceptibility to vibration and shock, and high price point leave much to be desired. To overcome the limitations of OFDR-based FOSS systems resulting from non-ideal excitation sources, NASA has developed a narrow linewidth solid-state laser based on the Distributed Feedback (DFB) laser. NASAs laser is continuously tuned by manipulating the laser cavitys temperature via a thermal-electric cooler feedback system. This continuous wavelength tuning generates a clean clock signal within an auxiliary interferometer, while the laser simultaneously interrogates multiple FBGs to produce a clean sensing interferometer. A Fourier domain spectrograph is used to show the unique frequency (i.e., location) of each FBG. While NASAs excitation source provides several performance advantages over conventional lasers used in OFDR, it is also highly compact and one eighth the cost of the ECLs traditionally used as excitation sources in OFDR-based systems. The laser has no moving parts, which also substantially improves system reliability. Originally developed to demonstrate a low-cost interrogator for liquid level sensing in oil tanks, NASAs compact, temperature-tuned OFDR laser can be applied wherever OFDR-based fiber optic sensing is desirable. Additional applications may include temperature distribution sensing, strain sensing, pressure sensing, and more. NASA AFRC has strong subject matter expertise in fiber optic sensing systems, and has developed several patented technologies that are available for commercial licensing. For more information about the full portfolio of FOSS technologies, visit: https://technology-afrc.ndc.nasa.gov/featurestory/fiber-optic-sensing

The new NASA LaRC Pulsed 2-Micron Laser Transmitter for Coherent 3-D Doppler Wind Lidar Systems is an innovative concept and architecture based on a Tm:Fiber laser end-pumped Ho:YAG laser transmitter. This transmitter meets the requirements for space-based coherent Doppler wind lidar while reducing the mission failure risks. A key advantage of this YAG based transmitter technology includes the fact that the design is based on mature and low-risk space-qualified YAG host crystal. The transmitter operates at a 2096 nm wavelength using Ho:YAG, resulting in high atmospheric transmission (>99%), versus a transmitter operating at 2053 nm using co- doped Tm:Ho:LuLiF, which suffers limited transmission (90%) due to water vapor interference. In-band pumping through Tm:Fiber pump Ho:YAG architecture offers lower quantum defect from 1908 to 2096 nm (9.1%) compared to traditionally used co-doped Tm:Ho:LuLiF of 792 to 2051 nm (61%). The transmitter has an efficient pump compared to LuLF, since YAG has 27% higher pump absorption and 52% lower reabsorption of the emitted 2-micron, resulting in higher efficiency and lower heat load. Being isotropic, YAG is amenable for spatial-hole burning mitigation which supports linear cavity architecture without compromising injection seeding quality. This attribute is important in designing a compact, stable, high seeding efficiency laser. A folded linear cavity for long pulse (>200 ns), transform limited line-width (2.2 MHz) and high beam quality (M2 = 1.04) - the most critical parameters for coherent detection - are easier to achieve using YAG compared to LuLF. Lower heat load results in high repetition rate (>300 Hz) operation, which allows higher probability of wind measurements through broken clouds, off clouds, and below clouds, thus reducing errors and increasing science data product quantity and quality.

This invention provides a new method for optical data transmissions from satellites using laser arrays for laser beam pointing. The system is simple, static, compact, and provides accurate pointing, acquisition, and tracking (PAT). It combines a lens system and a vertical-cavity surface-emitting laser VCSEL)/Photodetector Array, both mature technologies, in a novel way for PAT. It can improve the PAT system's size, weight, and power (SWaP) in comparison to current systems. Preliminary analysis indicates that this system is applicable to transmissions between satellites in low-Earth orbit (LEO) and ground terminals. Computer simulations using this design have been made for the application of this innovation to a CubeSat in LEO. The computer simulations included modeling the laser source and diffraction effects due to wave optics. The pointing used a diffraction limited lens system and a VCSEL array. These capabilities make it possible to model laser beam propagation over long space communication distances. Laser beam pointing is very challenging for LEO, including science missions. Current architectures use dynamical systems, (i.e., moving parts, e.g., fast-steering mirrors (FSM), and/or gimbals) to turn the laser to point to the ground terminal, and some use vibration isolation platforms as well. This static system has the potential to replace the current dynamic systems and vibration isolation platforms, dependent on studies for the particular application. For these electro-optical systems, reaction times to pointing changes and vibrations are on the nanosecond time scale, much faster than those for mechanical systems. For LEO terminals, slew rates are not a concern with this new system.

The conventional approaches for measuring focused laser differential interferometry either use a single-point mechanism that cannot calculate velocity or a system that creates non-parallel beams in the testing zone, causing differences in time to travel between beams throughout the testing zone, adding a level of uncertainty to velocity measurements. For this technology, the inventors determined that the best approach is to use a method that ensures all laser beams propagating between the transmitter and receiver sides of the instrument are parallel to one another. This is done by crossing two orthogonally polarized beams at a Wollaston prism located just ahead of the field lens on the transmitter side of the FLDI. The polarization orientation of the two crossing beams must be at 45 degrees to one another so that the Wollaston prism can further split the beams by a small angle (this gives the instrument its sensitivity to density fluctuations at each measurement point). The use of wedge prisms (that comprise the beam crossing system) to redirect the split beams such that they cross the optical axis minimizes any distortion imparted to the beams. This is in contrast to the use of a spherical focusing lens to redirect the split beams, which can impart undesirable distortions to the beams and affect the focusing properties of the FLDI instrument between its transmitter and receiver sides.

LWDC technology enables an improved channel wall nozzle with an outer liner that is fused to the inner liner to contain the coolant. It is an additive manufacturing technology that builds upon large-scale cladding techniques that have been used for many years in the oil and gas industry and in the repair industry for aerospace components. LWDC leverages wire freeform laser deposition to create features in place and to seal the coolant channels. It enables bimetallic components such as an internal copper liner with a superalloy jacket. LWDC begins when a fabricated liner made from one material, Material #1, is cladded with an interim Material #2 that sets up the base structure for channel slotting. A robotic and wire-based fused additive welding system creates a freeform shell on the outside of the liner. Building up from the base, the rotating weld head spools a bead of wire, closing out the coolant channels as the laser traverses circumferentially around the slotted liner. This creates a joint at the interface of the two materials that is reliable and repeatable. The LWDC wire and laser process is continued for each layer until the slotted liner is fully closed out without the need for any filler internal to the coolant channels. The micrograph on the left shows the quality of the bond at the interface of the channel edge and the closeout layer; on the right is a copper channel closed out with stainless.

A new method is described for optical data transmissions from satellites using laser arrays for fine pointing of laser beams that use body pointing. It combines a small lens system and a VCSEL/Photodetector Array in a novel way to provide a fine pointing capability for laser beams that are pointed by body pointing of a CubeSat. As Fig. 1 shows, an incoming laser beam (green or blue, with rightward arrows), transmitted from a ground terminal, enters the lens system, which directs it to an element of the pixel array (gray rectangle). Each element, or pixel, consists of a VCSEL component/photodetector pair. The photodetector detects the incoming beam, and the VCSEL component returns a modulated beam to the lens system (green or blue, with leftward arrows), which sends it to the ground terminal. As the incoming beam changes direction, e.g., from the blue to the green incoming direction, this change is detected by the adjacent photodetector, and the laser paired with that photodetector is turned on to keep the outgoing laser beam on target. The laser beams overlap so that the returning beam continues to point at the ground terminal. The VCSEL component may consist of a single VCSEL or a cluster of VCSELs. Figure 2 shows the propagation of two overlapping laser beams. The system can very accurately point finely focused diffraction-limited laser beams. Also, simultaneous optical multiple access (OMA) is possible from different transceivers within the area covered by the laser array. For this electro-optical system, reaction times to pointing changes and vibrations are on the nanosecond time scale, much faster than mechanical fine pointing systems.

This technology is based upon a 120-watt IR laser is coupled to a fiber optic cable that is routed from the output of the laser into a series of focusing optics which directs energy onto a battery cell mounted to a test stand. When activated, heat from the laser penetrates the metal housing, heating the internals of the cell. At a specific temperature, the separator in the first few layers of the cell melts allowing the anode and cathode to make contact and initiates an internal short circuit. The internal short circuit then propagates throughout the battery eventually causing thermal runaway. The lower the wavelength of the laser used to produce the thermal runaway, the more heat-energy will be absorbed into the cell producing a faster result. The fiber optic cable can be terminated into a series of optics to focus the laser at a specific target, or the fiber optic cable can be stripped bare and placed next to the target to heat an isolated location. This method can also be used on a wide variety of cells, including Li-ion pouch cells, Li-ion cylindrical cells and Li-ion Large format cells. The innovation Triggering Li-ion Cells with Laser Radiation is at TRL 6 (which means a system/subsystem prototype has been demonstrated in a relevant environment) and the related patent application is now available to license and develop into a commercial product. Please note that NASA does not manufacture products itself for commercial sale.

NASA's technology is the first successful 3D-printing of high temperature carbon fiber filled thermoset polyimide composites. Selective Laser Sintering (SLS) of carbon-filled RTM370 is followed by post-curing to achieve higher temperature capability, resulting in a composite part with a glass transition temperature of 370 °C. SLS typically uses thermoplastic polymeric powders and the resultant parts have a useful temperature range of 150-185 °C, while often being weaker compared to traditionally processed materials. Recently, higher temperature thermoplastics have been manufactured into 3D parts by high temperature SLS that requires a melting temperature of 380 °C, but the usable temperature range for these parts is still under 200 °C. NASA's thermoset polyimide composites are melt-processable between 150-240 °C, allowing the use of regular SLS machines. The resultant parts are subsequently post-cured using multi-step cycles that slowly heat the material to slightly below its glass transition temperature, while avoiding dimensional change during the process. This invention will greatly benefit aerospace companies in the production of parts with complex geometry for engine components requiring over 300 °C applications, while having a wealth of other potential applications including, but not limited to, printing legacy parts for military aircraft and producing components for high performance electric cars.

The NASA receiver is specifically designed for use in coherent LiDAR systems that leverage high-energy (i.e., > 1mJ) fiber laser transmitters. Within the receiver, an outgoing laser pulse from the high-energy laser transmitter is precisely manipulated using robust dielectric and coated optics including mirrors, waveplates, a beamsplitter, and a beam expander. These components appropriately condition and direct the high-energy light out of the instrument to the atmosphere for measurement. Lower energy atmospheric backscatter that returns to the system is captured, manipulated, and directed using several of the previously noted high-energy compatible bulk optics. The beam splitter redirects the return signal to mirrors and a waveplate ahead of a mode-matching component that couples the signal to a fiber optic cable that is routed to a 50/50 coupler photodetector. The receiver’s hybrid optic design capitalizes on the advantages of both high-energy bulk optics and fiber optics, resulting in order-of-magnitude enhancement in performance, enhanced functionality, and increased flexibility that make it ideal for long-distance or low-backscatter LiDAR applications. The related patent is now available to license. Please note that NASA does not manufacturer products itself for commercial sale.

NASA's ODS-MEA maintains properties up to 1100°C and is not susceptible to deleterious phase changes when exposed to extreme temperatures, an issue ubiquitous to Ni- based superalloys such as Inconel-625 and Inconel-718. Yttria particles are dispersed throughout the alloy to maximize strength and creep resistance at high temperatures using a novel fabrication technique. This technique employs an acoustic mixer to stir nano-scale Yttria oxide powder within a metallic matrix powder, creating a film of Yttria surrounding the larger metallic powder particles. Solid components are then produced from this mixture via SLM, during which the laser disperses the Yttria particles throughout the microstructure. Ultimately, the process eliminates the many expensive and time-consuming steps in the production of ODS alloys via traditional mechanical alloying. NASA's process has been shown to fabricate components with 10x improvement in creep rupture life at 1100°C and provides a 30% increase in strength over what is currently possible with 3D printed parts. The new ODS-MEA composition may find applications where ODS alloys are currently used (e.g., those involving extreme thermal environments). Applications may also include areas where such properties are desirable but the resource-intensive nature and/or inability to produce highly complex geometries via conventional processes ultimately renders their use uneconomical or infeasible. Such uses include gas turbine components (for which increasing inlet temperature enables improved efficiency) for power generation, propulsion (rockets, jet engines, etc.), industrial processes, nuclear energy applications, and sample preparation equipment in the mining and cement production industries, among many others.