In Situ X-Ray Observations of Dendritic Fragmentation During Directional Solidification of a Sn-Bi Alloy

DOE PAGES

Gibbs, John W.; Tourret, Damien; Gibbs, Paul J.; ...

2015-09-25

Dendrite fragmentation is an important phenomenon in microstructural development during solidification. For instance, it plays a key role in initiating the columnar-to-equiaxed transition (CET). In this paper, we use x-ray radiography to study dendrite fragmentation rate in a Sn-39.5 wt.% Bi alloy during directional solidification. Experiments were performed in which solidification was parallel and anti-parallel to gravity, leading to significantly different fragmentation rates. We quantify the distribution of fragmentation rate as a function of distance from the solidification front, time in the mushy zone, and volume fraction of solid. Finally, while the observed fragmentation rate can be high, there ismore » no evidence of a CET, illustrating that it requires more than just fragmentation to occur.« less

The effects of solidification on sill propagation dynamics and morphology

NASA Astrophysics Data System (ADS)

Chanceaux, L.; Menand, T.

2016-05-01

Sills are an integral part of the formation and development of larger plutons and magma reservoirs. Thus sills are essential for both the transport and the storage of magma in the Earth's crust. However, although cooling and solidification are central to magmatism, their effects on sills have been so far poorly studied. Here, the effects of solidification on sill propagation dynamics and morphology are studied by means of analogue laboratory experiments. Hot fluid vegetable oil (magma analogue), that solidifies during its propagation, is injected as a sill in a colder layered gelatine solid (elastic host rock analogue). The injection flux and temperature are maintained constant during an experiment and systematically varied between each experiment, in order to vary and quantify the amount of solidification between each experiments. The oil is injected directly at the interface between the two gelatine layers. When solidification effects are small (high injection temperatures and fluxes), the propagation is continuous and the sill has a regular and smooth surface. Inversely, when solidification effects are important (low injection temperatures and fluxes), sill propagation is discontinuous and occurs by steps of surface-area creation interspersed with periods of momentary arrest. The morphology of these sills displays folds, ropy structures on their surface, and lobes with imprints of the leading fronts that correspond to each step of area creation. These experiments show that for a given, constant injected volume, as solidification effects increase, the area of the sills decreases, their thickness increases, and the number of propagation steps increases. These results have various geological and geophysical implications. The morphology of sills, such as lobate structures (interpretation of 3D seismic studies in sedimentary basin) and ropy flow structures (field observations) can be related to solidification during emplacement. Moreover, a non-continuous morphology as observed in the field does not necessarily involve multiple injections, but could instead reflect a continuous, yet complex morphology induced by solidification effects during emplacement. Also, a discontinuous sill propagation induced by solidification effects should be associated with bursts of seismic activity. Finally, our study shows that once a sill has initiated, the dimensionless flux influences the sill thermal state, and in turn its propagation, and final extent and thickness. In restricting the lateral extent of sills, magma cooling and solidification are likely to impact directly the size of plutons constructed by amalgamated sills.

Spatiotemporal dynamics of oscillatory cellular patterns in three-dimensional directional solidification.

PubMed

Bergeon, N; Tourret, D; Chen, L; Debierre, J-M; Guérin, R; Ramirez, A; Billia, B; Karma, A; Trivedi, R

2013-05-31

We report results of directional solidification experiments conducted on board the International Space Station and quantitative phase-field modeling of those experiments. The experiments image for the first time in situ the spatially extended dynamics of three-dimensional cellular array patterns formed under microgravity conditions where fluid flow is suppressed. Experiments and phase-field simulations reveal the existence of oscillatory breathing modes with time periods of several 10's of minutes. Oscillating cells are usually noncoherent due to array disorder, with the exception of small areas where the array structure is regular and stable.

Convection Effects During Bulk Transparent Alloy Solidification in DECLIC-DSI and Phase-Field Simulations in Diffusive Conditions

NASA Astrophysics Data System (ADS)

Mota, F. L.; Song, Y.; Pereda, J.; Billia, B.; Tourret, D.; Debierre, J.-M.; Trivedi, R.; Karma, A.; Bergeon, N.

2017-08-01

To study the dynamical formation and evolution of cellular and dendritic arrays under diffusive growth conditions, three-dimensional (3D) directional solidification experiments were conducted in microgravity on a model transparent alloy onboard the International Space Station using the Directional Solidification Insert in the DEvice for the study of Critical LIquids and Crystallization. Selected experiments were repeated on Earth under gravity-driven fluid flow to evidence convection effects. Both radial and axial macrosegregation resulting from convection are observed in ground experiments, and primary spacings measured on Earth and microgravity experiments are noticeably different. The microgravity experiments provide unique benchmark data for numerical simulations of spatially extended pattern formation under diffusive growth conditions. The results of 3D phase-field simulations highlight the importance of accurately modeling thermal conditions that strongly influence the front recoil of the interface and the selection of the primary spacing. The modeling predictions are in good quantitative agreements with the microgravity experiments.

Space Processing Applications Rocket project, SPAR 1

NASA Technical Reports Server (NTRS)

Reeves, F. (Compiler); Chassay, R. (Compiler)

1976-01-01

The experiment objectives, design/operational concepts, and final results of each of nine scientific experiments conducted during the first Space Processing Applications Rocket (SPAR) flight are summarized. The nine individual SPAR experiments, covering a wide and varied range of scientific materials processing objectives, were entitled: solidification of Pb-Sb eutectic, feasibility of producing closed-cell metal foams, characterization of rocket vibration environment by measurement of mixing of two liquids, uniform dispersions of crystallization processing, direct observation of solidification as a function of gravity levels, casting thoria dispersion-strengthened interfaces, contained polycrystalline solidification, and preparation of a special alloy for manufacturing of magnetic hard superconductor under zero-g environment.

Ultrasound Flow Mapping for the Investigation of Crystal Growth.

PubMed

Thieme, Norman; Bonisch, Paul; Meier, Dagmar; Nauber, Richard; Buttner, Lars; Dadzis, Kaspars; Patzold, Olf; Sylla, Lamine; Czarske, Jurgen

2017-04-01

A high energy conversion and cost efficiency are keys for the transition to renewable energy sources, e.g., solar cells. The efficiency of multicrystalline solar cells can be improved by enhancing the understanding of its crystallization process, especially the directional solidification. In this paper, a novel measurement system for the characterization of flow phenomena and solidification processes in low-temperature model experiments on the basis of ultrasound (US) Doppler velocimetry is described. It captures turbulent flow phenomena in two planes with a frame rate of 3.5 Hz and tracks the shape of the solid-liquid interface during multihour experiments. Time-resolved flow mapping is performed using four linear US arrays with a total of 168 transducer elements. Long duration measurements are enabled through an online, field-programmable gate array (FPGA)-based signal processing. Nine single US transducers allow for in situ tracking of a solid-liquid interface. Results of flow and solidification experiments in the model experiment are presented and compared with numerical simulation. The potential of the developed US system for measuring turbulent flows and for tracking the solidification front during a directional crystallization process is demonstrated. The results of the model experiments are in good agreement with numerical calculations and can be used for the validation of numerical models, especially the selection of the turbulence model.

Effect of Processing Pressure on Isolated Pore Formation during Controlled Directional Solidification in Small Channels

NASA Technical Reports Server (NTRS)

Cox, Matthew C.; Anilkumar, Amrutur V.; Grugel, RIchard N.; Lee, Chun P.

2008-01-01

Directional solidification experiments were performed, using succinonitrile saturated with nitrogen gas, to examine the effects of in-situ processing pressure changes on the formation growth, and evolution of an isolated, cylindrical gaseous pore. A novel solidification facility, capable of processing thin cylindrical samples (I.D. < 1.0 mm), under controlled pressure conditions, was used for the experiments. A new experimental method for growing the isolated pore from a seed bubble is introduced. The experimental results indicate that an in-situ processing pressure change will result in either a transient change in pore diameter or a complete termination of pore growth, indicating that pressure changes can be used as a control parameter to terminate bubble growth. A simple analytical model has been introduced to explain the experimental observations.

KSC-97PC1462

NASA Image and Video Library

1997-09-15

United States Microgravity Payload-4 (USMP-4) experiments are prepared to be flown on Space Shuttle mission STS-87 in the Space Station Processing Facility at Kennedy Space Center (KSC). A technician is working on the Advanced Automated Directional Solidification Furnace (AADSF), which will be used by researchers to study the solidification of semiconductor materials in microgravity. Scientists will be able to better understand how microgravity influences the solidification process of these materials and develop better methods for controlling that process during future Space flights and Earth-based production. All STS-87 experiments are scheduled for launch on Nov. 19 from KSC

Comparative study of the influence of natural convection on directional solidification of Al 3.5 wt% Ni and Al 7 wt% Si alloys

NASA Astrophysics Data System (ADS)

Zhou, B. H.; Jung, H.; Mangelinck-Noël, N.; Nguyen-Thi, H.; Billia, B.; Liu, Q. S.; Lan, C. W.

We present numerical simulations of thermosolutal convection for directional solidification of Al 3.5 wt% Ni and Al 7 wt% Si. Numerical results predict that fragmentation of dendrite arms resulting from dissolution could be favored in Al 7 wt% Si, but not in Al 3.5 wt% Ni. Corresponding experiments are in qualitative agreement with the numerical predictions. Distinguishing the two fragmentation mechanisms, namely dissolution and remelting, is critical during experiments on earth, when fluid flow is dominant.

Space Processing Applications Rocket project, SPAR 2

NASA Technical Reports Server (NTRS)

1977-01-01

Experiment objectives, design/operational concepts, and final results are summarized for six materials science experiments conducted during the second space processing applications rocket mission flown by NASA. The individual experiments discussed are: (1) solidification of Pb-Sb eutectic; (2) feasibility of producing closed-cell metal foams; (3) direct observation of dendrite remelting and macrosegregation in castings; (4) agglomeration in immiscible liquids; (5) casting dispersion - strengthened composites at zero gravity; and (6) solidification behavior of Al-In alloys under zero gravity conditions.

Development Of A Magnetic Directional-Solidification Furnace

NASA Technical Reports Server (NTRS)

Aldrich, Bill R.; Lehoczky, Sandor L.

1996-01-01

Report describes development of directional-solidification furnace in which axial magnetic field is imposed by surrounding ring permanent magnets and/or electromagnets and pole pieces. Furnace provides controlled axial temperature gradients in multiple zones, through which ampoule containing sample of material to be solidified is translated at controlled speed by low-vibration, lead-screw, stepping-motor-driven mechanism. Intended for use in low-gravity (spaceflight) experiments on melt growth of high-purity semiconductor crystals.

Growth of Solid Solution Single Crystals

NASA Technical Reports Server (NTRS)

Lehoczky, Sandor L.; Szofran, F. R.; Gillies, Donald C.

2001-01-01

The solidification of a solid solution semiconductor, having a wide separation between liquidus and solidus has been extensively studied in ground based, high magnetic field and Spacelab experiments. Two alloys of mercury cadmium telluride have been studied; with 80.0 mole percent of HgTe and 84.8 mole percent of HgTe respectively, the remainder being cadmium telluride. Such alloys are extremely difficult to grow by directional solidification on earth due to high solutal and thermal density differences that give rise to fluid flow and consequent loss of interface shape and composition. Diffusion controlled growth is therefore impossible to achieve in conventional directional solidification. The ground based experiments consisted of growing crystals in several different configurations of heat pipe furnaces, NASA's Advanced Automated Directional Solidification Furnace (AADSF), and a similar furnace incorporated in a superconducting magnet capable of operating at up to 5T. The first microgravity experiment took place during the flight of STS-62 in March 1994, with the AADSF installed on the second United States Microgravity Payload (USMP-2). The alloy was solidified at 3/4 inch per day over a 9 day period, and for the first time a detailed evaluation was performed correlating composition variations to measured residual acceleration. The second flight experiment took place in the fourth United States Microgravity Payload Mission (USMP-4) in November 1997. Due to contamination of the furnace system, analysis shows that the conditions prevailing during the experiment were quite different from the requirements requested prior to the mission. The results indicate that the sample did accomplish the desired objectives.

Macrosegregation Resulting from Directional Solidification Through an Abrupt Change in Cross-Sections

NASA Technical Reports Server (NTRS)

Lauer, M.; Poirier, D. R.; Ghods, M.; Tewari, S. N.; Grugel, R. N.

2017-01-01

Simulations of the directional solidification of two hypoeutectic alloys (Al-7Si alloy and Al-19Cu) and resulting macrosegregation patterns are presented. The casting geometries include abrupt changes in cross-section from a larger width of 9.5 mm to a narrower 3.2 mm width then through an expansion back to a width of 9.5 mm. The alloys were chosen as model alloys because they have similar solidification shrinkages, but the effect of Cu on changing the density of the liquid alloy is about an order of magnitude greater than that of Si. The simulations compare well with experimental castings that were directionally solidified in a graphite mold in a Bridgman furnace. In addition to the simulations of the directional solidification in graphite molds, some simulations were effected for solidification in an alumina mold. This study showed that the mold must be included in numerical simulations of directional solidification because of its effect on the temperature field and solidification. For the model alloys used for the study, the simulations clearly show the interaction of the convection field with the solidifying alloys to produce a macrosegregation pattern known as "steepling" in sections with a uniform width. Details of the complex convection- and segregation-patterns at both the contraction and expansion of the cross-sectional area are revealed by the computer simulations. The convection and solidification through the expansions suggest a possible mechanism for the formation of stray grains. The computer simulations and the experimental castings have been part of on-going ground-based research with the goal of providing necessary background for eventual experiments aboard the ISS. For casting practitioners, the results of the simulations demonstrate that computer simulations should be applied to reveal interactions between alloy solidification properties, solidification conditions, and mold geometries on macrosegregation. The simulations also presents the possibility of engineering the mold-material to avoid, or mitigate, the effects of thermosolutal convection and macrosegregation by selecting a mold material with suitable thermal properties, especially its thermal conductivity.

Technicians monitor USMP-4 experiments being prepared for flight on STS-87 in the SSPF

NASA Technical Reports Server (NTRS)

1997-01-01

Technicians are monitoring experiments on the United States Microgravity Payload-4 (USMP-4) in preparation for its scheduled launch aboard STS-87 on Nov. 19 from Kennedy Space Center (KSC). USMP-4 experiments are prepared in the Space Station Processing Facility at KSC. The large white vertical cylinder at the right of the photo is the Advanced Automated Directional Solidification Furnace (AADSF ), which is a sophisticated materials science facility used for studying a common method of processing semiconductor crystals called directional solidification. The technician in the middle of the photo is leaning over MEPHISTO, a cooperative American-French investigation of the fundamentals of crystal growth.

Fluid mechanics of directional solidification at reduced gravity

NASA Technical Reports Server (NTRS)

Chen, C. F.

1992-01-01

The primary objective of the proposed research is to provide additional groundbased support for the flight experiment 'Casting and Solidification Technology' (CAST). This experiment is to be performed in the International Microgravity Laboratory-1 (IML-1) scheduled to be flown on a space shuttle mission scheduled for 1992. In particular, we will provide data on the convective motion and freckle formation during directional solidification of NH4Cl from its aqueous solution at simulated parameter ranges equivalent to reducing the gravity from the sea-level value down to 0.1 g or lower. The secondary objectives of the proposed research are to examine the stability phenomena associated with the onset of freckles and the mechanisms for their subsequent growth and decline (to eventual demise of some) by state-of-the-art imaging techniques and to formulate mathematical models for the prediction of the observed phenomena.

Bubble Induced Disruption of a Planar Solid-Liquid Interface During Controlled Directional Solidification in a Microgravity Environment

NASA Technical Reports Server (NTRS)

Grugel, Richard N.; Brush, Lucien N.; Anilkumar, Amrutur V.

2013-01-01

Pore Formation and Mobility Investigation (PFMI) experiments were conducted in the microgravity environment aboard the International Space Station with the intent of better understanding the role entrained porosity/bubbles play during controlled directional solidification. The planar interface in a slowing growing succinonitrile - 0.24 wt% water alloy was being observed when a nitrogen bubble traversed the mushy zone and remained at the solid-liquid interface. Breakdown of the interface to shallow cells subsequently occurred, and was later evaluated using down-linked data from a nearby thermocouple. These results and other detrimental effects due to the presence of bubbles during solidification processing in a microgravity environment are presented and discussed.

Interface Pattern Selection Criterion for Cellular Structures in Directional Solidification

NASA Technical Reports Server (NTRS)

Trivedi, R.; Tewari, S. N.; Kurtze, D.

1999-01-01

The aim of this investigation is to establish key scientific concepts that govern the selection of cellular and dendritic patterns during the directional solidification of alloys. We shall first address scientific concepts that are crucial in the selection of interface patterns. Next, the results of ground-based experimental studies in the Al-4.0 wt % Cu system will be described. Both experimental studies and theoretical calculations will be presented to establish the need for microgravity experiments.

Phase Field Modeling of Microstructure Development in Microgravity

NASA Technical Reports Server (NTRS)

Dantzig, Jonathan A.; Goldenfeld, Nigel

2001-01-01

This newly funded project seeks to extend our NASA-sponsored project on modeling of dendritic microstructures to facilitate collaboration between our research group and those of other NASA investigators. In our ongoing program, we have applied advanced computational techniques to study microstructural evolution in dendritic solidification, for both pure isolated dendrites and directionally solidified alloys. This work has enabled us to compute dendritic microstructures using both realistic material parameters and experimentally relevant processing conditions, thus allowing for the first time direct comparison of phase field computations with laboratory observations. This work has been well received by the materials science and physics communities, and has led to several opportunities for collaboration with scientists working on experimental investigations of pattern selection and segregation in solidification. While we have been able to pursue these collaborations to a limited extent, with some important findings, this project focuses specifically on those collaborations. We have two target collaborations: with Prof. Glicksman's group working on the Isothermal Dendritic Growth Experiment (IDGE), and with Prof. Poirier's group studying directional solidification in Pb-Sb alloys. These two space experiments match well with our two thrusts in modeling, one for pure materials, as in the IDGE, and the other directional solidification. Such collaboration will benefit all of the research groups involved, and will provide for rapid dissemination of the results of our work where it will have significant impact.

Controlled Directional Solidification of Aluminum - 7 wt Percent Silicon Alloys: Comparison Between Samples Processed on Earth and in the Microgravity Environment Aboard the International Space Station

NASA Technical Reports Server (NTRS)

Grugel, Richard N.; Tewari, Surendra N.; Erdman, Robert G.; Poirier, David R.

2012-01-01

An overview of the international "MIcrostructure Formation in CASTing of Technical Alloys" (MICAST) program is given. Directional solidification processing of metals and alloys is described, and why experiments conducted in the microgravity environment aboard the International Space Station (ISS) are expected to promote our understanding of this commercially relevant practice. Microstructural differences observed when comparing the aluminum - 7 wt% silicon alloys directionally solidified on Earth to those aboard the ISS are presented and discussed.

A laboratory model for solidification of Earth's core

NASA Astrophysics Data System (ADS)

Bergman, Michael I.; Macleod-Silberstein, Marget; Haskel, Michael; Chandler, Benjamin; Akpan, Nsikan

2005-11-01

To better understand the influence of rotating convection in the outer core on the solidification of the inner core we have constructed a laboratory model for solidification of Earth's core. The model consists of a 15 cm radius hemispherical acrylic tank concentric with a 5 cm radius hemispherical aluminum heat exchanger that serves as the incipient inner core onto which we freeze ice from salt water. Long exposure photographs of neutrally buoyant particles in illuminated planes suggest reduction of flow parallel to the rotation axis. Thermistors in the tank near the heat exchanger show that in experiments with rotation the temperature near the pole is lower than near the equator, unlike for control experiments without rotation or with a polymer that increases the fluid viscosity. The photographs and thermistors suggest that our observation that ice grows faster near the pole than near the equator for experiments with rotation is a result of colder water not readily convecting away from the pole. Because of the reversal of the thermal gradient, we expect faster equatorial solidification in the Earth's core. Such anisotropy in solidification has been suggested as a cause of inner core elastic (and attenuation) anisotropy, though the plausibility of this suggestion will depend on the core Nusselt number and the slope of the liquidus, and the effects of post-solidification deformation. Previous experiments on hexagonal close-packed alloys such as sea ice and zinc-tin have shown that fluid flow in the melt can result in a solidification texture transverse to the solidification direction, with the texture depending on the nature of the flow. A comparison of the visualized flow and the texture of columnar ice crystals in thin sections from these experiments confirms flow-induced transverse textures. This suggests that the convective pattern at the base of the outer core is recorded in the texture of the inner core, and that outer core convection might contribute to the complexity in the seismically inferred pattern of anisotropy in the Earth's inner core.

Improved Crystal Quality by Detached Solidification in Microgravity

NASA Technical Reports Server (NTRS)

Regel, Liya L.; Wilcox, William R.

1999-01-01

Directional solidification in microgravity has often led to ingots that grew with little or no contact with the ampoule wall. When this occurred, crystallographic perfection was usually greatly improved -- often by several orders of magnitude. Unfortunately, until recently the true mechanisms underlying detached solidification were unknown. As a consequence, flight experiments yielded erratic results. Within the past four years, we have developed a new theoretical model that explains many of the flight results. This model gives rise to predictions of the conditions required to yield detached solidification, both in microgravity and on earth. A discussion of models of detachment, the meniscus models and results of theoretical modeling, and future plans are presented.

The influence of gravity level during directional solidification of immiscible alloys

NASA Technical Reports Server (NTRS)

Andrews, J. B.; Schmale, A. L.; Sandlin, A. C.

1992-01-01

During directional solidification of immiscible (hypermonotectic) alloys it is theoretically possible to establish a stable macroscopically-planar solidification front, and thus avoid sedimentation. Unfortunately, convective instabilities often occur which interfere with the directional solidification process. In this paper, stability conditions are discussed and results presented from directional solidification studies carried out aboard NASA's KC-135 zero-g aircraft. Samples were directionally solidified while the effective gravity level was varied from approximately 0.01 g for 25 s to 1.8 g for 45 s. Dramatic variations in microstructure were observed with gravity level during solidification.

In-Situ Monitoring of a Bismuth-Tin Alloy Solidification Using MEPHISTO

NASA Technical Reports Server (NTRS)

Abbaschian, Reza; Beatty, Kirk M.; Chen, Fuwang; deGroh, Henry, III; Cambon, Gerard

1999-01-01

Experiments were carried out to study the morphological stability of Bi- 1 atomic % Sn alloys using the MEPHISTO directional solidification apparatus aboard Space Shuttle Columbia (STS-87, launched Nov. 19, 1997) and in ground-based studies. The Seebeck signal and temperature measurements indicate that convection was significant for ground-based studies. In the space-based experiments, interface breakdown was observed at growth velocities of 6.7, 27, and 40 microns/sec, but not at 1.8 and 3.3 microns/sec.

Microgravity

NASA Image and Video Library

1997-11-01

The purpose of the experiments for the Advanced Automated Directional Solidification Furnace (AADSF) is to determine how gravity-driven convection affects the composition and properties of alloys (mixtures of two or more materials, usually metal). During the USMP-4 mission, the AADSF will solidify crystals of lead tin telluride and mercury cadmium telluride, alloys of compound semiconductor materials used to make infrared detectors and lasers, as experiment samples. Although these materials are used for the same type application their properties and compositional uniformity are affected differently during the solidification process.

Modeling of Detached Solidification

NASA Technical Reports Server (NTRS)

Regel, Liya L.; Wilcox, William R.; Popov, Dmitri

1997-01-01

Our long term goal is to develop techniques to achieve detached solidification reliably and reproducibly, in order to produce crystals with fewer defects. To achieve this goal it is necessary to understand thoroughly the physics of detached solidification. It was the primary objective of the current project to make progress toward this complete understanding. 'Me products of this grant are attached. These include 4 papers and a preliminary survey of the observations of detached solidification in space. We have successfully modeled steady state detached solidification, examined the stability of detachment, and determined the influence of buoyancy-driven convection under different conditions. Directional solidification in microgravity has often led to ingots that grew with little or no contact with the ampoule wall. When this occurred, crystallographic perfection was usually greatly improved -- often by several orders of magnitude. Indeed, under the Soviet microgravity program the major objective was to achieve detached solidification with its resulting improvement in perfection and properties. Unfortunately, until recently the true mechanisms underlying detached solidification were unknown. As a consequence, flight experiments yielded erratic results. Within the past three years, we have developed a new theoretical model that explains many of the flight results. This model gives rise to predictions of the conditions required to yield detached solidification.

Modelling directional solidification

NASA Technical Reports Server (NTRS)

Wilcox, William R.

1991-01-01

The long range goal of this program is to develop an improved understanding of phenomena of importance to directional solidification and to enable explanation and prediction of differences in behavior between solidification on Earth and in space. Current emphasis is on determining the influence of perturbations on directional solidification.

Modelling Directional Solidification

NASA Technical Reports Server (NTRS)

Wilcox, William R.; Regel, Liya L.; Zhou, Jian; Yuan, Weijun

1992-01-01

The long range goal of this program has been to develop an improved understanding of phenomena of importance to directional solidification, in order to enable explanation and prediction of differences in behavior between solidification on Earth and in space. Current emphasis is on determining the influence of perturbations on directional solidification.

Particle Engulfment and Pushing by Solidifying Interfaces LMS Mission Results

NASA Technical Reports Server (NTRS)

Juretzko, Frank R.; Catalina, Adrian V.; Stefanescu, Doru M.; Dhindaw, Brij K.; Sen, Subhayu; Curreri, Peter A.; Mullins, Jennifer

1998-01-01

Results of the directional solidification experiments on Particle Engulfment and Pushing by Solidifying Interfaces (PEP) conducted on the space shuttle Columbia are reported. The experiment was manifested as part of The Life and Microgravity Science Mission. Two pure aluminum (99.999%) 9 mm cylindrical rods, loaded with about 2 vol.% 500 microns diameter zirconia particles were melted and directionally solidified in the microgravity (micro-g) environment of the shuttle. The particles were non-reactive with the matrices within the temperature range of interest. The experiments were conducted such as to insure a planar solid/liquid interface during solidification. Two different cartridge - crucible - sample designs were used: a spring-piston and expansion void. Both resulted in sound samples. Samples were evaluated post-flight for soundness by X-ray computer tomography (XCT).

Materials Science Laboratory - Columnar-to-Equiaxed Transition in Solidification Processing and Microstructure Formation in Casting of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions

NASA Technical Reports Server (NTRS)

Gandin, Charles-Andre; Ratke, Lorenz

2008-01-01

The Materials Science Laboratory - Columnar-to-Equiaxed Transition in Solidification Processing and Microstructure Formation in Casting of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions (MSL-CETSOL and MICAST) are two investigations which supports research into metallurgical solidification, semiconductor crystal growth (Bridgman and zone melting), and measurement of thermo-physical properties of materials. This is a cooperative investigation with the European Space Agency (ESA) and National Aeronautics and Space Administration (NASA) for accommodation and operation aboard the International Space Station (ISS). Research Summary: Materials Science Laboratory - Columnar-to-Equiaxed Transition in Solidification Processing (CETSOL) and Microstructure Formation in Casting of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions (MICAST) are two complementary investigations which will examine different growth patterns and evolution of microstructures during crystallization of metallic alloys in microgravity. The aim of these experiments is to deepen the quantitative understanding of the physical principles that govern solidification processes in cast alloys by directional solidification.

Solidification processing of monotectic alloy matrix composites

NASA Technical Reports Server (NTRS)

Frier, Nancy L.; Shiohara, Yuh; Russell, Kenneth C.

1989-01-01

Directionally solidified aluminum-indium alloys of the monotectic composition were found to form an in situ rod composite which obeys a lambda exp 2 R = constant relation. The experimental data shows good agreement with previously reported results. A theoretical boundary between cellular and dendritic growth conditions was derived and compared with experiments. The unique wetting characteristics of the monotectic alloys can be utilized to tailor the interface structure in metal matrix composites. Metal matrix composites with monotectic and hypermonotectic Al-In matrices were made by pressure infiltration, remelted and directionally solidified to observe the wetting characteristics of the alloys as well as the effect on structure of solidification in the constrained field of the fiber interstices. Models for monotectic growth are modified to take into account solidification in these constrained fields.

Direct observation of spatially isothermal equiaxed solidification of an Al-Cu alloy in microgravity on board the MASER 13 sounding rocket

NASA Astrophysics Data System (ADS)

Murphy, A. G.; Mathiesen, R. H.; Houltz, Y.; Li, J.; Lockowandt, C.; Henriksson, K.; Melville, N.; Browne, D. J.

2016-11-01

For the first time, isothermal equiaxed solidification of a metallic alloy has been observed in situ in space, providing unique benchmark experimental data. The experiment was completed on board the MASER 13 sounding rocket, launched in December 2015, using a newly developed isothermal solidification furnace. A grain-refined Al-20 wt%Cu sample was fully melted and solidified during 360 s of microgravity and the solidification sequence was recorded using time-resolved X-radiography. Equiaxed nucleation, dendritic growth, solutal impingement, and eutectic transformation were thus observed in a gravity-free environment. Equiaxed nucleation was promoted through application of a controlled cooling rate of -0.05 K/s producing a 1D grain density of 6.5 mm-1, uniformly distributed throughout the field of view (FOV). Primary growth slowed to a visually imperceptible level at an estimated undercooling of 7 K, after which the cooling rate was increased to -1.0 K/s for the remainder of solidification and eutectic transformation, ensuring the sample was fully solidified inside the microgravity time window. The eutectic transformation commenced at the centre of the FOV proceeding radially outwards covering the entire FOV in 3 s Microgravity-based solidification is compared to an identical pre-flight ground-based experiment using the same sample and experiment timeline. The ground experiment was designed to minimise gravity effects, by choice of a horizontal orientation for the sample, so that any differences would be subtle. The first equiaxed nucleation occurred at an apparent undercooling of 0.6 K less than the equivalent event during microgravity. During primary equiaxed solidification, as expected, no buoyant grain motion was observed during microgravity, compared to modest grain rotation and reorientation observed during terrestrial-based solidification. However, when the cooling rate was increased from -0.05 K/s to -1.0 K/s during the latter stages of solidification, in both 1g and micro-g environments, some grain movement was apparent due to liquid feeding and mechanical impingement of neighbouring grains.

Preliminary science report on the directional solidification of hypereutectic cast iron during KC-135 low-G maneuvers

NASA Technical Reports Server (NTRS)

Curreri, P. A.; Stefanescu, D. M.; Hendrix, J. C.

1983-01-01

An ADSS-P directional solidification furnace was reconfigured for operation on the KC-135 low-g aircraft. The system offers many advantages over quench ingot methods for study of the effects of sedimentation and convection on alloy formation. The directional sodification furnace system was first flown during the September 1982 series of flights. The microstructure of the hypereutectic cast iron sample solidified on one of these flights suggests a low-g effect on graphite morphology. Further experiments are needed to ascertain that this effect is due to low-gravity and to deduce which of the possible mechanisms is responsible for it.

Particle Engulfment and Pushing by Solidification Interfaces. Part 1; Ground Experiments

NASA Technical Reports Server (NTRS)

Juretzko, Frank R.; Dhindaw, Brij K.; Stefanescu, Doru M.; Sen, subhayu; Curreri, Peter A.

1998-01-01

Directional solidification experiments have been carried out to determine the pushing/engulfment transition for two different metal/particle systems. The systems chosen were aluminum/zirconia particles and zinc/zirconia particles. Pure metals (99.999% Al and 99.95% Zn) and spherical particles (500 microns in diameter) were used. The particles were non-reactive with the matrices within the temperature range of interest. The experiments were conducted such as to insure a planar solid/liquid interface during solidification. Particle location before and after processing was evaluated by X-ray transmission microscopy for the Al/ZrO2 samples. All samples were characterized by optical metallography after processing. A clear methodology for the experiment evaluation was developed to unambiguously interpret the occurrence of the pushing/engulfment transition. It was found that the critical velocity for engulfment ranges from 1.9 to 2.4 micron/s for Al/ZrO2 and from 1.9 to 2.9 microns/s for Zn/ZrO2.

Experimental Study on the Anisotropic Stress-Strain Behavior of Polycrystalline Ni-Mn-Ga in Directional Solidification

NASA Astrophysics Data System (ADS)

Teng, Yao; Shi, Tao; Zhu, Yuping; Li, Zongbin; Deng, Tao; Bai, Guonan

2016-03-01

A polycrystalline Ni-Mn-Ga ferromagnetic shape memory alloy produced by directional solidification is the subject of this research paper. The compressive stress-strain curves of the material for different cutting angles to the solidification direction are tested. The martensite Young's modulus, macroscopic reorientation strain, and phase transition critical stress are analyzed experimentally. The results show that mechanical behaviors in the loading-unloading cycle of the material present nonlinear and anisotropic characteristics, which are all closely related to the material's orientation to the solidification direction. The martensite Young's modulus, macroscopic reorientation strain, and phase transition critical stress achieve maximum values in the solidification direction. A 50° orientation to the solidification direction is the cut-off direction of the mechanical properties, where the martensite Young's modulus and reorientation start critical stress reach minimum values. The present study is expected to provide sound guidance for practical applications.

Onset of Curved Dendrite Growth in an Al-Cu Welding Pool: A Phase Field Study

NASA Astrophysics Data System (ADS)

Wang, Lei; Wei, Yanhong

2018-02-01

A phase field model is developed to predict curved dendrite growth in the gas tungsten arc (GTA) welding pool of an Al-Cu alloy. The equations of temperature gradient, pulling velocity and dendrite growth orientation are proposed to consider the transient solidification process during welding. Solidification microstructures and solute diffusion along the fusion boundary in the welding pool are predicted by using the phase field model coupled with transient solidification conditions. Predicted primary dendrites are curved and point toward the welding direction. Welding experiments are carried out to observe solidification microstructures of the weld. Comparisons of simulation results with experimental measurements are conducted. Predicted dendritic morphology, dendrite growth orientation, primary dendrite arm spacing and initial cell spacing give a good agreement with experimental measurements.

Space- and Ground-Based Crystal Growth Using a Baffle (CGB)

NASA Technical Reports Server (NTRS)

Ostrogorsky, A. G.; Marin, C.; Peignier, T.; Duffar, T.; Volz, M.; Jeter, L.; Luz, P.

2001-01-01

The composition of semiconductor crystals produced in space by conventional melt-growth processes (directional solidification and zone melting) is affected by minute levels of residual micro-acceleration, which causes natural convection. The residual acceleration has random magnitude, direction and frequency. Therefore, the velocity field in the melt is apriori unpredictable. As a result, the composition of the crystals grown in space can not be predicted and reproduced. The method for directional solidification with a submerged heater or a baffle was developed under NASA sponsorship. The disk-shaped baffle acts as a partition, creating a small melt zone at the solid-liquid interface. As a result, in ground based experiment the level of buoyancy-driven convection at the interface is significantly reduced. In several experiments with Te-doped GaSb, nearly diffusion controlled segregation was achieved.

Shape selection criterion for cellular array during constrained growth of binary alloys - Need for low gravity experiment

NASA Technical Reports Server (NTRS)

Tewari, Surendra N.; Trivedi, Rohit

1991-01-01

Development of steady-state periodic cellular array is one of the critical problems in the study of nonlinear pattern formation during directional solidification of binary alloys. The criterion which establishes the values of cell tip radius and spacing under given growth condition is not known. Theoretical models, such as marginal stability and microscopic solvability, have been developed for purely diffusive regime. However, the experimental conditions where cellular structures are stable are precisely the ones where the convection effects are predominant. Thus, the critical data for meaningful evaluation of cellular array growth models can only be obtained by partial directional solidification and quenching experiments carried out in the low gravity environment of space.

Heat treatment study 2

NASA Technical Reports Server (NTRS)

Workman, Gary L.

1990-01-01

The microstructural variations in nickel based superalloys that result from modifications in processing were examined. These superalloys include MAR-M246(HF) and PWA1480. Alternate heat treatments for equiaxed as-cast specimens were studied and a sample matrix of 42 variations in the heat treatments were processed, as well as different directional solidification parameters. Variation in temperature and times for both solution and aging were performed. Photomicrographs were made of the microstructure and volume fraction analysis of primary gamma-prime and aged gamma-prime precipitates were performed. The results of the heat treatment, cooling rate, and directional solidification experiments are discussed.

XRMON-GF: A novel facility for solidification of metallic alloys with in situ and time-resolved X-ray radiographic characterization in microgravity conditions

NASA Astrophysics Data System (ADS)

Nguyen-Thi, H.; Reinhart, G.; Salloum Abou Jaoude, G.; Mathiesen, R. H.; Zimmermann, G.; Houltz, Y.; Voss, D.; Verga, A.; Browne, D. J.; Murphy, A. G.

2013-07-01

As most of the phenomena involved during the growth of metallic alloys from the melt are dynamic, in situ and time-resolved X-ray imaging should be retained as the method of choice for investigating the solidification front evolution. On Earth, the gravity force is the major source of various disturbing effects (natural convection, buoyancy/sedimentation, and hydrostatic pressure) which can significantly modify or mask certain physical mechanisms. Therefore solidification under microgravity is an efficient way to eliminate such perturbations to provide unique benchmark data for the validation of models and numerical simulations. Up to now, in situ observation during microgravity solidification experiments were limited to the investigations on transparent organic alloys, using optical methods. On the other hand, in situ observation on metallic alloys generally required synchrotron facilities. This paper reports on a novel facility we have designed and developed to investigate directional solidification on metallic alloys in microgravity conditions with in situ X-ray radiography observation. The facility consists of a Bridgman furnace and an X-ray radiography device specifically devoted to the study of Al-based alloys. An unprecedented experiment was recently performed on board a sounding rocket, with a 6 min period of microgravity. Radiographs were successfully recorded during the entire experiment including the melting and solidification phases of the sample, with a Field-of-View of about 5 mm×5 mm, a spatial resolution of about 4 µm and a frequency of 2 frames per second. Some preliminary results are presented on the solidification of the Al-20 wt% Cu sample, which validate the apparatus and confirm the potential of in situ X-ray characterization for the investigation of dynamical phenomena in materials processing, and particularly for the studying of metallic alloys solidification.

Phase-field modelling of β(Ti) solidification in Ti-45at.%Al: columnar dendrite growth at various gravity levels

NASA Astrophysics Data System (ADS)

Viardin, A.; Berger, R.; Sturz, L.; Apel, M.; Hecht, U.

2016-03-01

The effect of solutal convection on the solidification of γ titanium aluminides, specifically on β(Ti) dendrite growth, is not well known. With the aim of supporting directional solidification experiments under hyper-gravity using a large diameter centrifuge, 2D-phase field simulations of β(Ti) dendrite growth have been performed for the binary alloy Ti-45at.%Al and various gravity scenarios. Both, the direction and magnitude of the gravity vector were varied systematically in order to reveal the subtle interplay between the convective flow pattern and mushy zone characteristics. In this presentation, gravity effects are discussed for early dendrite growth. For selected cases the evolution on longer timescales is also analyse of and oscillatory modes leading to dynamically stable steady state growth are outlined. In a dedicated simulation series forced flow is superimposed, as to mimic thermally driven fluid flow expected to establish on the macroscopic scale (sample size) in the centrifugal experiments. Above a certain threshold this flow turns dominant and precludes solutally driven convective effects.

Directional Solidification of Mercury Cadmium Telluride During the Second United States Microgravity Payload Mission (USMP-2)

NASA Technical Reports Server (NTRS)

Gillies, D. C.; Lehoczky, S. L.; Szofran, F. R.; Watring, D. A.; Alexander, H. A.; Jerman, G. A.

1996-01-01

As a solid solution semiconductor having, a large separation between liquidus and solidus, mercury cadmium telluride (MCT) presents a formidable challenge to crystal growers desiring an alloy of high compositional uniformity. To avoid constitutional supercooling during Bridgman crystal growth it is necessary to solidify slowly in a high temperature gradient region. The necessary translation rate of less than 1 mm/hr results in a situation where fluid flow induced by gravity on earth is a significant factor in material transport. The Advanced Automated Directional Solidification Furnace (AADSF) is equipped to provide the stable thermal environment with a high gradient, and the required slow translation rate needed. Ground based experiments in AADSF show clearly the dominance of flow driven transport. The first flight of AADSF in low gravity on USMP-2 provided an opportunity to test theories of fluid flow in MCT and showed several solidification regimes which are very different from those observed on earth. Residual acceleration vectors in the orbiter during the mission were measured by the Orbital Acceleration Research Experiment (OARE), and correlated well with observed compositional differences in the samples.

The Effect of Microgravity Direction on the Growth of PbSnTe

NASA Technical Reports Server (NTRS)

Fripp, A. L.; Debnam, W. J.; Rosch, W. R.; Narayanan, R.

1998-01-01

The Space Shuttle Columbia was launched as STS-75 at 2018 GMT (Greenwich Mean Time) on February 22, 1996. One of the two major experiment packages was the Third United States Microgravity Payload (USMP-3), and one of the principal instruments on the USMP was the Advanced Automated Directional Solidification Furnace (AADSF). The AADSF is a multizone directional solidification furnace, and at the time of the USMP-3 flight was capable of processing only one sample per Shuttle mission which, for that flight, was a lead tin telluride (PbSnTe) crystal growth experiment. In the one year since the flight experiment the sample has been retrieved from the spacecraft and analysis has begun. After presenting introductory material on why PbSnTe was chosen as a test material, why microgravity processing was expected to produce desired results, and what we expected to find in conducting these tests, this report discusses the results to date which are far from complete.

Analysis of Residual Acceleration Effects on Transport and Segregation During Directional Solidification of Tin-Bismuth in the MEPHISTO Furnace Facility

NASA Technical Reports Server (NTRS)

Alexander J. Iwan D. (Principal Investigator)

1996-01-01

The objective of this work is to approach the problem of determining the transport conditions (and effects of residual acceleration) during the plane-front directional solidification of a tin-bismuth alloy under low gravity conditions. The work involves using a combination of 2- and 3-D numerical models, scaling analyses, ID models and the results of ground-based and low-gravity experiments. The latter are to be conducted during the MEPHISTO experiment scheduled for USMP-3 in early 1996. The models will be used to predict the response of the transport conditions and consequent solute segregation in directionally solidifying tin-bismuth melt. Real-time Seebeck voltage variations across a Sn-Bi melt during directional solidification in MEPHISTO on USMP-1 show a distinct variation which can be correlated with thruster firings. The Seebeck voltage measurement is related to the response of the instantaneous average melt composition at the melt-solid interface. This allows a direct comparison of numerical simulations with the Seebeck signals obtained on USMP-1. The effects of such accelerations on composition for a directionally solidifying Sn-Bi alloy have been simulated numerically. USMP-1 acceleration data was used to assist in our choice of acceleration magnitude and orientation. The results show good agreement with experimental observations. The USMP-3 experiments took place earlier this year (February 22 through March 6). There were several differences between the USMP-3 experiments as compared to USMP-1. Firstly a more concentrated alloy was solidified and, secondly, Primary Reaction Control System thruster burns were requested at particular times during four separate growth runs. This allowed us to monitor the response Seebeck response under well-characterized growth conditions. In addition, we carried out simulations during the experiment in order to interpret the Seebeck signal. Preliminary results are described here.

Investigation of the growth of directionally solidified eutectics with potential as electron emitters

NASA Technical Reports Server (NTRS)

Chapman, A. T.; Cochran, J. K.

1976-01-01

The construction of a solar furnace was completed and it was tested after a preliminary alignment of the heliostat mirrors. After final alignment, the solar furnace is used for directional solidification experiments designed to simulate space conditions.

Three-dimensional Dendritic Needle Network model with application to Al-Cu directional solidification experiments

NASA Astrophysics Data System (ADS)

Tourret, D.; Karma, A.; Clarke, A. J.; Gibbs, P. J.; Imhoff, S. D.

2015-06-01

We present a three-dimensional (3D) extension of a previously proposed multi-scale Dendritic Needle Network (DNN) approach for the growth of complex dendritic microstructures. Using a new formulation of the DNN dynamics equations for dendritic paraboloid-branches of a given thickness, one can directly extend the DNN approach to 3D modeling. We validate this new formulation against known scaling laws and analytical solutions that describe the early transient and steady-state growth regimes, respectively. Finally, we compare the predictions of the model to in situ X-ray imaging of Al-Cu alloy solidification experiments. The comparison shows a very good quantitative agreement between 3D simulations and thin sample experiments. It also highlights the importance of full 3D modeling to accurately predict the primary dendrite arm spacing that is significantly over-estimated by 2D simulations.

Three-dimensional Dendritic Needle Network model with application to Al-Cu directional solidification experiments

DOE PAGES

Tourret, D.; Karma, A.; Clarke, A. J.; ...

2015-06-11

We present a three-dimensional (3D) extension of a previously proposed multi-scale Dendritic Needle Network (DNN) approach for the growth of complex dendritic microstructures. Using a new formulation of the DNN dynamics equations for dendritic paraboloid-branches of a given thickness, one can directly extend the DNN approach to 3D modeling. We validate this new formulation against known scaling laws and analytical solutions that describe the early transient and steady-state growth regimes, respectively. Finally, we compare the predictions of the model to in situ X-ray imaging of Al-Cu alloy solidification experiments. The comparison shows a very good quantitative agreement between 3D simulationsmore » and thin sample experiments. It also highlights the importance of full 3D modeling to accurately predict the primary dendrite arm spacing that is significantly over-estimated by 2D simulations.« less

Phase-field simulation of weld solidification microstructure in an Al Cu alloy

NASA Astrophysics Data System (ADS)

Farzadi, A.; Do-Quang, M.; Serajzadeh, S.; Kokabi, A. H.; Amberg, G.

2008-09-01

Since the mechanical properties and the integrity of the weld metal depend on the solidification behaviour and the resulting microstructural characteristics, understanding weld pool solidification is of importance to engineers and scientists. Thermal and fluid flow conditions affect the weld pool geometry and solidification parameters. During solidification of the weld pool, a columnar grain structure develops in the weld metal. Prediction of the formation of the microstructure during welding may be an important and supporting factor for technology optimization. Nowadays, increasing computing power allows direct simulations of the dendritic and cell morphology of columnar grains in the molten zone for specific temperature conditions. In this study, the solidification microstructures of the weld pool at different locations along the fusion boundary are simulated during gas tungsten arc welding of Al-3wt%Cu alloy using the phase-field model for the directional solidification of dilute binary alloys. A macroscopic heat transfer and fluid flow model was developed to assess the solidification parameters, notably the temperature gradient and solidification growth rate. The effect of the welding speed is investigated. Computer simulations of the solidification conditions and the formation of a cellular morphology during the directional solidification in gas tungsten arc welding are described. Moreover, the simulation results are compared with existing theoretical models and experimental findings.

Natural convection in the Hale-Shaw cell of horizontal Bridgman solidification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lu, Y.; Liu, J.; Zhou, Y.

1995-08-01

The numerical simulation of natural convection in the Hale-Shaw cell during horizontal Bridgman solidification reveals that the convection is present even for the very thin cell. The effects of the horizontal temperature gradient, G, thickness of the cell, H, temperature difference between the top and bottom of the cell, and other parameters have been studied. These findings have been confirmed by experiments through direct observation and measurement of convection in the cell containing succinonitrile transparent model alloy.

Design of model experiments for melt flow and solidification in a square container under time-dependent magnetic fields

NASA Astrophysics Data System (ADS)

Meier, D.; Lukin, G.; Thieme, N.; Bönisch, P.; Dadzis, K.; Büttner, L.; Pätzold, O.; Czarske, J.; Stelter, M.

2017-03-01

This paper describes novel equipment for model experiments designed for detailed studies on electromagnetically driven flows as well as solidification and melting processes with low-melting metals in a square-based container. Such model experiments are relevant for a validation of numerical flow simulation, in particular in the field of directional solidification of multi-crystalline photovoltaic silicon ingots. The equipment includes two square-shaped electromagnetic coils and a melt container with a base of 220×220 mm2 and thermostat-controlled heat exchangers at top and bottom. A system for dual-plane, spatial- and time-resolved flow measurements as well as for in-situ tracking of the solid-liquid interface is developed on the basis of the ultrasound Doppler velocimetry. The parameters of the model experiment are chosen to meet the scaling laws for a transfer of experimental results to real silicon growth processes. The eutectic GaInSn alloy and elemental gallium with melting points of 10.5 °C and 29.8 °C, respectively, are used as model substances. Results of experiments for testing the equipment are presented and discussed.

Numerical Simulation and Optimization of Directional Solidification Process of Single Crystal Superalloy Casting

PubMed Central

Zhang, Hang; Xu, Qingyan; Liu, Baicheng

2014-01-01

The rapid development of numerical modeling techniques has led to more accurate results in modeling metal solidification processes. In this study, the cellular automaton-finite difference (CA-FD) method was used to simulate the directional solidification (DS) process of single crystal (SX) superalloy blade samples. Experiments were carried out to validate the simulation results. Meanwhile, an intelligent model based on fuzzy control theory was built to optimize the complicate DS process. Several key parameters, such as mushy zone width and temperature difference at the cast-mold interface, were recognized as the input variables. The input variables were functioned with the multivariable fuzzy rule to get the output adjustment of withdrawal rate (v) (a key technological parameter). The multivariable fuzzy rule was built, based on the structure feature of casting, such as the relationship between section area, and the delay time of the temperature change response by changing v, and the professional experience of the operator as well. Then, the fuzzy controlling model coupled with CA-FD method could be used to optimize v in real-time during the manufacturing process. The optimized process was proven to be more flexible and adaptive for a steady and stray-grain free DS process. PMID:28788535

Materials processing in space, 1980 science planning document. [crystal growth, containerless processing, solidification, bioprocessing, and ultrahigh vacuum processes

NASA Technical Reports Server (NTRS)

Naumann, R. J.

1980-01-01

The scientific aspects of the Materials Processing in Space program are described with emphasis on the major categories of interest: (1) crystal growth; (2) solidification of metals, alloys, and composites; (3) fluids and chemical processes; (4) containerless processing, glasses, and refractories; (5) ultrahigh vacuum processes; and (6) bioprocessing. An index is provided for each of these areas. The possible contributions that materials science experiments in space can make to the various disciplines are summarized, and the necessity for performing experiments in space is justified. What has been learned from previous experiments relating to space processing, current investigations, and remaining issues that require resolution are discussed. Recommendations for the future direction of the program are included.

Influence of a magnetic field during directional solidification of MAR-M 246 + Hf superalloy

NASA Technical Reports Server (NTRS)

Andrews, J. Barry; Alter, Wendy; Schmidt, Dianne

1991-01-01

An area that has been almost totally overlooked in the optimization of properties in directionally solidified superalloys is the control of microstructural features through the application of a magnetic field during solidification. The influence of a magnetic field on the microstructural features of a nickel-base superalloys is investigated. Studies were performed on the dendritic MAR-M 246+Hf alloy, which was solidified under both a 5 K gauss magnetic field and under no-applied-field conditions. The possible influences of the magnetic field on the solidification process were observed by studying variations in microstructural features including volume fraction, surface area, number, and shape of the carbide particles. Stereological factors analyzed also included primary and secondary dendrite arm spacing and the volume fraction of the interdendritic eutectic constituent. Microprobe analysis was performed to determine the chemistry of the carbides, dendrites, and interdendritic constituents, and how it varied between field and no-field solidification samples. Experiments involving periodic application and removal of the magnetic field were also performed in order to permit a comparison with structural variations observed in a MAR-M 246+Hf alloy solidified during KC-135 high-g, low-g maneuvers.

Space Processing Applications Rocket (SPAR) project: SPAR 10

NASA Technical Reports Server (NTRS)

Poorman, R. (Compiler)

1986-01-01

The Space Processing Applications Rocket Project (SPAR) X Final Report contains the compilation of the post-flight reports from each of the Principal Investigators (PIs) on the four selected science payloads, in addition to the engineering report as documented by the Marshall Space Flight Center (MSFC). This combined effort also describes pertinent portions of ground-based research leading to the ultimate selection of the flight sample composition, including design, fabrication and testing, all of which are expected to contribute to an improved comprehension of materials processing in space. The SPAR project was coordinated and managed by MSFC as part of the Microgravity Science and Applications (MSA) program of the Office of Space Science and Applications (OSSA) of NASA Headquarters. This technical memorandum is directed entirely to the payload manifest flown in the tenth of a series of SPAR flights conducted at the White Sands Missile Range (WSMR) and includes the experiments entitled, Containerless Processing Technology, SPAR Experiment 76-20/3; Directional Solidification of Magnetic Composites, SPAR Experiment 76-22/3; Comparative Alloy Solidification, SPAR Experiment 76-36/3; and Foam Copper, SPAR Experiment 77-9/1R.

Directional Solidification of Bi-Sn on USMP-4

NASA Technical Reports Server (NTRS)

Abbaschian, Reza; deGroh, H., III; Leonardi, E.; Timchenko, V.; deVahlDavis, G.

1999-01-01

The experiments used MEPHISTO hardware to study the solidification and melting behavior of bismuth alloyed with 1 at% tin. Three samples, each approximately 900 mm long and 6mm in diameter, were used. A portion of each sample also included a 2 mm diameter growth capillary, to assist in the formation of a single grain. One sample provided the Seebeck voltage generated during melting and freezing processes. Another provided temperature data and Peltier pulsed demarcation of the interface shape for post flight analysis. The third sample provided resistance and growth velocity measurements, as well as additional thermal data. The third sample was also quenched at the end of the mission to preserve the composition of the liquid near the interface for post flight determination. A total of 450mm of directionally solidified samples were preserved for post mission structural and compositional characterization. Substantial differences were observed in the Seebeck signal between the ground-based experiments and the space-based experiments. The temperature gradient in the liquid for the ground-based experiments was significantly lower than the temperature gradient in the liquid for the space-based experiments.

Microsegregation during directional solidification

NASA Technical Reports Server (NTRS)

Coriell, S. R.; Mcfadden, G. B.

1984-01-01

During the directional solidification of alloys, solute inhomogeneities transverse to the growth direction arise due to morphological instabilities (leading to cellular or dendritic growth) and/or due to convection in the melt. In the absence of convection, the conditions for the onset of morphological instability are given by the linear stability analysis of Mullins and Sekerka. For ordinary solidification rates, the predictions of linear stability analysis are similar to the constitutional supercooling criterion. However, at very rapid solidification rates, linear stability analysis predicts a vast increase in stabilization in comparison to constitutional supercooling.

Quantitative determination of zero-gravity effects on electronic materials processing germanium crystal growth with simultaneous interface demarcation. Experiment MA-060

NASA Technical Reports Server (NTRS)

Gatos, H. C.; Witt, A. F.

1977-01-01

Experiment MA-060 was designed to establish the crystal growth and segregation characteristics of a melt in a directional solidification configuration under near zero-g conditions. The interface demarcation technique was incorporated into the experiment since it constitutes a unique tool for recording the morphology of the growth rate throughout solidification, and for establishing an absolute time reference framework for all stages of the solidification process. An extensive study was performed of the germanium crystals grown during the Apollo-Soyuz Test Project mission. It was found that single crystal growth was achieved and that the interface demarcation functioned successfully. There was no indication that convection driven by thermal or surface tension gradients was present in the melt. The gallium segregation, in the absence of gravity, was found to be fundamentally different in its initial and its subsequent stages from that of the ground-based tests. None of the existing theoretical models for growth and segregation can account for the observed segregation behavior in the absence of gravity.

Eutectic Experiment Development for Space Processing

NASA Technical Reports Server (NTRS)

Hopkins, R. H.

1972-01-01

A ground base test plan and a specimen evaluation scheme have been developed for the aluminum-copper eutectic solidification experiment to be run in the M518 multipurpose electric furnace during the Skylab mission. Besides thermal and solidification studies a detailed description is given of the quantitative metallographic technique which is appropriate for characterizing eutectic structures. This method should prove a key tool for evaluating specimen microstructure which is the most sensitive indicator of changes produced during solidification. It has been recommended that single grain pre-frozen eutectic specimens be used to simplify microstructural evaluation and to eliminate any porosity in the as-cast eutectic specimens. High purity (99.999%) materials from one supplier should be employed for all experiments. Laboratory studies indicate that porosity occurs in the MRC as-cast eutectic ingots but that this porosity can be eliminated by directional freezing. Chemical analysis shows that the MRC ingots are slightly Al rich and contain about .03% impurity. Because of the impurity content the lower cooldown rate (1.2 C/min) should be used for eutectic freezing if MRC material is used in the M518 furnace.

The Pore Formation and Mobility Investigation: A Case Study for Conducting Research on the International Space Station in Support of Exploration

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Luz, P.; Smith, G. A.; Spivey, R.; Mingo, C.; Jeter, L.; Volz, M. P.

2005-01-01

The Pore Formation and Mobility Investigation (PFMI) is being conducted in the Microgravity Science Glovebox (MSG) aboard the International Space Station (ISS) with the goal of understanding bubble generation and interactions during controlled directional solidification processing. Through the course of the experiments, beginning in September 2002, a number of key factors pertinent to solidification processing of materials in a microgravity environment have been directly observed, measured, and modeled. Though most experiments ran uninterrupted, on four separate occasions malfunctions to the PFMI hardware and software were experienced that required crew intervention, including in-space repair. Fortunately, each repair attempt was successful and restored the PFMI apparatus to a fully functional condition. Based on PFMI results and lessons learned, the intent of this presentation is to draw attention to the role ISS experiments/hardware can play in providing insight to potential fabrication processing techniques and repair scenarios that might arise during long duration space transport and/or on the lunar/Mars surface.

The Pore Formation and Mobility Investigation: A Summary of Conducted Research on the International Space Station

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Luz, P.; Smith, G. A.; Spivey, R.; Jeter, L.; Volz, M. P.; Anilkumar, A.

2006-01-01

The Pore Formation and Mobility Investigation (PFMI) is being conducted in the Microgravity Science Glovebox (MSG) aboard the International Space Station (ISS) with the goal of understanding bubble generation and interactions during controlled directional solidification processing. Through the course of the experiments, beginning in September 2002, a number of key factors pertinent to solidification processing of materials in a microgravity environment have been directly observed, measured, and modeled. Though most experiments ran uninterrupted, on four separate occasions malfunctions to the PFMI hardware and software were experienced that required crew intervention, including in-space repair. Fortunately, each repair attempt was successful and restored the PFMI apparatus to a fully functional condition. Based on PFMI results and lessons learned, the intent of this presentation is to draw attention to the role ISS experiments/hardware can play in providing insight to potential fabrication processing techniques and repair scenarios that might arise during long duration space transport and/or on the lunar/Mars surface.

Analysis of Residual Acceleration Effects on Transport and Segregation During Directional Solidification of Tin-Bismuth in the MEPHISTO Furnace Facility

NASA Technical Reports Server (NTRS)

Alexander, J. Iwan D.

1998-01-01

The research accomplishments summarized in this Final Report during the period from 3/95 to 3/98, which included a 12 months no-cost extension granted at the end of the nominal 2 year period of performance. The report has 5 sections, in section 1 the objectives are presented, a task description is given and the background and significance of the work is outlined. In section 2 the research accomplishments are summarized. In section 3 publications and presentations are listed. Student participation is listed in 4. The work is summarized in section 5. and references for sections 1 and 2 are supplied in section 6. The object of this work, is to approach the problem of determining the transport conditions (and effects of residual acceleration) during the plane-front directional solidification of a tin-bismuth alloy under low gravity conditions. The work involved using a combination of 2- and 3-D numerical models, scaling analyses, ID models and the results of ground-based and low-gravity experiments. The experiments conducted in the MEPHISTO furnace facility during the USW-3 space flight which took place between February 22 through March 6, 199). This experiment represents an unprecedented opportunity to make a quantitative correlation between residual accelerations and the response of an actual experimental solidification

Effect of Stepwise Pressure Change on Porosity Evolution during Directional Solidification in Small Cylindrical Channels

NASA Technical Reports Server (NTRS)

Grugel, R.N.; Lee, C.P.; Cox, M.C.; Blandford, B.T.; Anilkumar, A.V.

2008-01-01

Controlled directional solidification experiments were performed in capillary channels, using nitrogen-saturated succinonitrile, to examine the effect of an in-situ stepwise processing pressure increase on an isolated pore evolution. Two experiments were performed using different processing pressure input profiles. The results indicate that a processing pressure increase has a transient effect on pore growth geometry characterized by an initial phase of decreasing pore diameter, followed by a recovery phase of increasing pore diameter. The experimental results also show that processing pressure can be used as a control parameter to either increase or terminate porosity formation. A theoretical model is introduced which indicates that the pore formation process is limited by the diffusion of solute-gas through the melt, and that the observed response toa pressure increase is attributed to the re-equilibration of solute concentration in the melt associated with the increased melt pressure.

Modelling direction solidification

NASA Technical Reports Server (NTRS)

Wilcox, W. R.

1986-01-01

The overall objective of this program is to develop an improved understanding of some phenomena of importance to directional solidification. The aim of this research is also to help predict differences in behavior between solidification on Earth and solidification in space. In this report, the validity of the Burton-Primslichter equation is explored. The influence of operating variables on grain and twin generation and propagation in single crystals of In sub (x) Ga sub (1-x) Sb is also investigated.

Melt Flow Control in the Directional Solidification of Binary Alloys

NASA Technical Reports Server (NTRS)

Zabaras, Nicholas

2003-01-01

Our main project objectives are to develop computational techniques based on inverse problem theory that can be used to design directional solidification processes that lead to desired temperature gradient and growth conditions at the freezing front at various levels of gravity. It is known that control of these conditions plays a significant role in the selection of the form and scale of the obtained solidification microstructures. Emphasis is given on the control of the effects of various melt flow mechanisms on the local to the solidification front conditions. The thermal boundary conditions (furnace design) as well as the magnitude and direction of an externally applied magnetic field are the main design variables. We will highlight computational design models for sharp front solidification models and briefly discuss work in progress toward the development of design techniques for multi-phase volume-averaging based solidification models.

Effect of the temperature-rate parameters of directional solidification on the structure formation in high-temperature materials

NASA Astrophysics Data System (ADS)

Svetlov, I. L.; Neiman, A. V.

2017-03-01

The effect of the temperature gradient and the crystal growth rate on the structure formation in nickel and niobium superalloys is studied under the conditions of the flat, cellular, dendritic, or dendritic-cellular configuration of a solidification front during directional solidification.

Microgravity

NASA Image and Video Library

1991-09-01

The Advanced Automated Directional Solidification Furnace (AADSF) flew during the USMP-2 mission. During USMP-2, the AADSF was used to study the growth of mercury cadmium telluride crystals in microgravity by directional solidification, a process commonly used on earth to process metals and grow crystals. The furnace is tubular and has three independently controlled temperature zones. The sample travels from the hot zone of the furnace (1600 degrees F) where the material solidifies as it cools. The solidification region, known as the solid/liquid interface, moves from one end of the sample to the other at a controlled rate, thus the term directional solidification.

Modelling directional solidification

NASA Technical Reports Server (NTRS)

Wilcox, William R.; Regel, Liya L.

1994-01-01

This grant, NAG8-831, was a continuation of a previous grant, NAG8-541. The long range goal of this program has been to develop an improved understanding of phenomena of importance to directional solidification, in order to enable explanation and prediction of differences in behavior between solidification on Earth and in space. Emphasis in the recently completed grant was on determining the influence of perturbations on directional solidification of InSb and InSb-GaSb alloys. In particular, the objective was to determine the influence of spin-up/spin-down (ACRT), electric current pulses and vibrations on compositional homogeneity and grain size.

Reduction in secondary dendrite arm spacing in cast eutectic Al-Si piston alloys by cerium addition

NASA Astrophysics Data System (ADS)

Ahmad, R.; Asmael, M. B. A.; Shahizan, N. R.; Gandouz, S.

2017-01-01

The effects of Ce on the secondary dendrite arm spacing (SDAS) and mechanical behavior of Al-Si-Cu-Mg alloys were investigated. The reduction of SDAS at different Ce concentrations was evaluated in a directional solidification experiment via computer-aided cooling curve thermal analysis (CA‒CCTA). The results showed that 0.1wt%-1.0wt% Ce addition resulted in a rapid solidification time, Δ t s, and low solidification temperature, Δ T S, whereas 0.1wt% Ce resulted in a fast solidification time, Δ t a-Al, of the α-Al phase. Furthermore, Ce addition refined the SDAS, which was reduced to approximately 36%. The mechanical properties of the alloys with and without Ce were investigated using tensile and hardness tests. The quality index ( Q) and ultimate tensile strength of (UTS) Al-Si-Cu-Mg alloys significantly improved with the addition of 0.1wt% Ce. Moreover, the base alloy hardness was improved with increasing Ce concentration.

Evolution of solidification texture during additive manufacturing.

PubMed

Wei, H L; Mazumder, J; DebRoy, T

2015-11-10

Striking differences in the solidification textures of a nickel based alloy owing to changes in laser scanning pattern during additive manufacturing are examined based on theory and experimental data. Understanding and controlling texture are important because it affects mechanical and chemical properties. Solidification texture depends on the local heat flow directions and competitive grain growth in one of the six <100> preferred growth directions in face centered cubic alloys. Therefore, the heat flow directions are examined for various laser beam scanning patterns based on numerical modeling of heat transfer and fluid flow in three dimensions. Here we show that numerical modeling can not only provide a deeper understanding of the solidification growth patterns during the additive manufacturing, it also serves as a basis for customizing solidification textures which are important for properties and performance of components.

The growth of metastable peritectic compounds

NASA Technical Reports Server (NTRS)

Larson, D. J., Jr.

1984-01-01

The influence of gravitationally driven convection on the directional solidification of peritectic alloys was evaluated. The Pb-Bi peritectic was studied as a model solidification system. Analyses of directionally solidified Pb-Bi peritectic samples indicate that appreciable macrosegregation occurs due to thermosolutal convection and/or Soret diffusion. The macrosegregation results in sequantial change of phase and morphology as solidification progresses down the length of the sample. Banding was eliminated when furnace conditions were selected which resulted in a planar solidification interface. The directional solidification that occurs in the vicinity of the Pb-Bi peritectic isothermal was found to be isocompositional and to consist solely of the equilibrium terminal solid solution and peritectic phases on an extremely fine scale. Evidence was found to support the peritectic supercooling mechanism, but not the proposed peritectic superheat mechanism.

Effect of a High Magnetic Field on γ' Phase for Ni-Based Single Crystal Superalloy During Directional Solidification

NASA Astrophysics Data System (ADS)

Xuan, Weidong; Lan, Jian; Zhao, Dengke; Li, Chuanjun; Shang, Xingfu; Zhong, Yunbo; Li, Xi; Ren, Zhongming

2018-05-01

The effect of a high magnetic field on the γ' phase of Ni-based single crystal superalloy during directional solidification is investigated experimentally. The results clearly indicate that the magnetic field significantly reduces the γ' phase size. Further, the quenching experiment is carried out, and the results found that the length of mushy zone is obviously decreased under a high magnetic field. Based on both experimental results and nucleation mechanism, it is found that the decrease of γ' phase size should be attributed to the fact that a high magnetic field causes the increase of temperature gradient in front of solid/liquid interface and leads to the increase of undercooling of γ' phase.

High temperature furnace modeling and performance verifications

NASA Technical Reports Server (NTRS)

Smith, James E., Jr.

1992-01-01

Analytical, numerical, and experimental studies were performed on two classes of high temperature materials processing sources for their potential use as directional solidification furnaces. The research concentrated on a commercially available high temperature furnace using a zirconia ceramic tube as the heating element and an Arc Furnace based on a tube welder. The first objective was to assemble the zirconia furnace and construct parts needed to successfully perform experiments. The 2nd objective was to evaluate the zirconia furnace performance as a directional solidification furnace element. The 3rd objective was to establish a data base on materials used in the furnace construction, with particular emphasis on emissivities, transmissivities, and absorptivities as functions of wavelength and temperature. A 1-D and 2-D spectral radiation heat transfer model was developed for comparison with standard modeling techniques, and were used to predict wall and crucible temperatures. The 4th objective addressed the development of a SINDA model for the Arc Furnace and was used to design sample holders and to estimate cooling media temperatures for the steady state operation of the furnace. And, the 5th objective addressed the initial performance evaluation of the Arc Furnace and associated equipment for directional solidification. Results of these objectives are presented.

Microgravity

NASA Image and Video Library

1992-03-12

The Advanced Automated Directional Solidification Furnace (AADSF) with the Experimental Apparatus Container (EAC) removed flew during the USMP-2 mission. During USMP-2, the AADSF was used to study the growth of mercury cadmium telluride crystals in microgravity by directional solidification, a process commonly used on earth to process metals and grow crystals. The furnace is tubular and has three independently controlled temperature zones . The sample travels from the hot zone of the furnace (1600 degrees F) where the material solidifies as it cools. The solidification region, known as the solid/liquid interface, moves from one end of the sample to the other at a controlled rate, thus the term directional solidification.

KSC-97PC1458

NASA Image and Video Library

1997-09-15

United States Microgravity Payload-4 (USMP-4) experiments are prepared to be flown on Space Shuttle mission STS-87 in the Space Station Processing Facility at Kennedy Space Center (KSC). The large white vertical cylinder in the center of the photo is the Advanced Automated Directional Solidification Furnace (AADSF) and the horizontal tube to the left of it is MEPHISTO, a French acronym for a cooperative American-French investigation of the fundamentals of crystal growth. Seen at right behind the AADSF in the circular white cover is the Isothermal Dendritic Growth Experiment (IDGE), which will be used to study the dendritic solidification of molten materials in the microgravity environment. Under the multi-layer insulation with the American flag and mission logo is the Space Acceleration Measurement System, or SAMS, which measures the microgravity conditions in which the experiments are conducted. All of these experiments are scheduled for launch aboard STS-87 on Nov. 19 from KSC

KSC-97PC1461

NASA Image and Video Library

1997-09-15

United States Microgravity Payload-4 (USMP-4) experiments are prepared to be flown on Space Shuttle mission STS-87 in the Space Station Processing Facility at Kennedy Space Center (KSC). The large white vertical cylinder in the middle of the photo is the Advanced Automated Directional Solidification Furnace (AADSF) and the horizontal tube to its left is MEPHISTO, the French acronym for a cooperative American-French investigation of the fundamentals of crystal growth. Seen to the right of the AADSF is the Isothermal Dendritic Growth Experiment (IDGE), which will be used to study the dendritic solidification of molten materials in the microgravity environment. Under the multi-layer insulation with the American flag and mission logo is the Space Acceleration Measurement System, or SAMS, which measures the microgravity conditions in which the experiments are conducted. All of these experiments are scheduled for launch aboard STS-87 on Nov. 19 from KSC

Study of Interesting Solidification Phenomena on the Ground and in Space (MEPHISTO)

NASA Technical Reports Server (NTRS)

Alexander, J. Iwan D.; Favier, J.-J.; Garandet, J.-P.

1999-01-01

Real-time Seebeck voltage variations in a Sn-Bi melt during directional solidification in the MEPHISTO spaceflight experiment flown on the USMP-3 mission, have been correlated with well-characterized thruster firings and an Orbiter Main System (OMS) burn. The Seebeck voltage measurement is related to the response of the instantaneous average melt composition at the melt-crystal interface. This allowed us to make a direct comparison of numerical simulations with the experimentally obtained Seebeck signals. Based on the results of preflight and real-time computations, several well-defined thruster firing events were programmed to occur at specific times during the experiment. In particular, we simulated the effects of the thruster firings on melt and crystal composition in a directionally solidifying Sn-Bi alloy. The relative accelerations produced by the firings were simulated by impulsive accelerations of the same magnitude, duration and orientation as the requested firings. A comparison of the simulation results with the Seebeck signal indicates that there is a good agreement between the two. This unique opportunity allows us to make the first quantitative characterization of actual g-jitter effects on an actual crystal growth experiment and to calibrate our models of g-jitter effects on crystal growth.

Study of Interesting Solidification Phenomena on the Ground and in Space (MEPHISTO)

NASA Technical Reports Server (NTRS)

Favier, J.-J.; Iwan, J.; Alexander, D.; Garandet, J.-P.

1998-01-01

Real-time Seebeck voltage variations in a Sn-Bi melt during directional solidification in the MEPHISTO spaceflight experiment flown on the USMP-3 mission, can be correlated with well characterized thruster firings and an Orbiter Main System (OMS) burn. The Seebeck voltage measurement is related to the response of the instantaneous average melt composition at the melt-crystal interface. This allowed us to make a direct comparison of numerical simulations with the experimentally obtained Seebeck signals. Based on the results of preflight and real-time computations, several well-defined thruster firing events were programmed to occur at specific times during the experiment. In particular, we simulated the effects of the thruster firings on melt and crystal composition in a directionally solidifying Sn-Bi alloy. The relative accelerations produced by the firings were simulated by impulsive accelerations of the same magnitude, duration and orientation as the requested firings. A comparison of the simulation results with the Seebeck signal indicates that there is a good agreement between the two. This unique opportunity allows us, for the first time, to quantitatively characterize actual g-jitter effects on an actual crystal growth experiment and to properly calibrate our models of g-jitter effects on crystal growth.

Evolution of solidification texture during additive manufacturing

PubMed Central

Wei, H. L.; Mazumder, J.; DebRoy, T.

2015-01-01

Striking differences in the solidification textures of a nickel based alloy owing to changes in laser scanning pattern during additive manufacturing are examined based on theory and experimental data. Understanding and controlling texture are important because it affects mechanical and chemical properties. Solidification texture depends on the local heat flow directions and competitive grain growth in one of the six <100> preferred growth directions in face centered cubic alloys. Therefore, the heat flow directions are examined for various laser beam scanning patterns based on numerical modeling of heat transfer and fluid flow in three dimensions. Here we show that numerical modeling can not only provide a deeper understanding of the solidification growth patterns during the additive manufacturing, it also serves as a basis for customizing solidification textures which are important for properties and performance of components. PMID:26553246

Evolution of solidification texture during additive manufacturing

DOE PAGES

Wei, H. L.; Mazumder, J.; DebRoy, T.

2015-11-10

Striking differences in the solidification textures of a nickel based alloy owing to changes in laser scanning pattern during additive manufacturing are examined based on theory and experimental data. Understanding and controlling texture are important because it affects mechanical and chemical properties. Solidification texture depends on the local heat flow directions and competitive grain growth in one of the six <100> preferred growth directions in face centered cubic alloys. Furthermore, the heat flow directions are examined for various laser beam scanning patterns based on numerical modeling of heat transfer and fluid flow in three dimensions. Here we show that numericalmore » modeling can not only provide a deeper understanding of the solidification growth patterns during the additive manufacturing, it also serves as a basis for customizing solidification textures which are important for properties and performance of components.« less

Microstructural Development during Directional Solidification of Peritectic Alloys

NASA Technical Reports Server (NTRS)

Lograsso, Thomas A.

1996-01-01

A thorough understanding of the microstructures produced through solidification in peritectic systems has yet to be achieved, even though a large number of industrially and scientifically significant materials are in this class. One type of microstructure frequently observed during directional solidification consists of alternating layers of primary solid and peritectic solid oriented perpendicular to the growth direction. This layer formation is usually reported for alloy compositions within the two-phase region of the peritectic isotherm and for temperature gradient and growth rate conditions that result in a planar solid-liquid interface. Layered growth in peritectic alloys has not previously been characterized on a quantitative basis, nor has a mechanism for its formation been verified. The mechanisms that have been proposed for layer formation can be categorized as either extrinsic or intrinsic to the alloy system. The extrinsic mechanisms rely on externally induced perturbations to the system for layer formation, such as temperature oscillations, growth velocity variations, or vibrations. The intrinsic mechanisms approach layer formation as an alternative type of two phase growth that is inherent for certain peritectic systems and solidification conditions. Convective mixing of the liquid is an additional variable which can strongly influence the development and appearance of layers due to the requisite slow growth rate. The first quantitative description of layer formation is a model recently developed by Trivedi based on the intrinsic mechanism of cyclic accumulation and depiction of solute in the liquid ahead of the interface, linked to repeated nucleation events in the absence of convection. The objective of this research is to characterize the layered microstructures developed during ground-based experiments in which external influences have been minimized as much as possible and to compare these results to the current the model. Also, the differences between intrinsic and externally influenced layer formation were explored. The choice of alloy system is critical to a study of the formation of layered microstructures. The ideal system would have a well-characterized phase diagram, equal densities of both elements in the liquid state to minimize compositionally-driven convective flows, a low peritectic temperature to simplify directional solidification and the achievement of a high temperature gradient in the liquid, a broad composition range for the peritectic reaction, and a reasonable hardness at room temperature to facilitate handling and metallographic preparation. The In-Sn system was selected initially due to a very low peritectic temperature and the nearly equal densities of In and Sn in the liquid state. Since the In-rich peritectic reaction had apparently not been utilized previously for solidification research, experiments were conducted to check the phase diagram in the region of interest. The alloys in this system proved to be difficult to handle and prepare in bulk form with the equipment available, so experiments were initiated with the Sn-Cd system. Layered microstructures had been observed previously in Sn-Cd.

Dendrite Array Disruption by Bubbles during Re-melting in a Microgravity Environment

NASA Technical Reports Server (NTRS)

Grugel, Richard N.

2012-01-01

As part of the Pore Formation and Mobility Investigation (PFMI), Succinonitrile Water alloys consisting of aligned dendritic arrays were re-melted prior to conducting directional solidification experiments in the microgravity environment aboard the International Space Station. Thermocapillary convection initiated by bubbles at the solid-liquid interface during controlled melt back of the alloy was observed to disrupt the initial dendritic alignment. Disruption ranged from detaching large arrays to the transport of small dendrite fragments at the interface. The role of bubble size and origin is discussed along with subsequent consequences upon reinitiating controlled solidification.

Numerical simulation of freckle formation in directional solidification of binary alloys

NASA Technical Reports Server (NTRS)

Felicelli, Sergio D.; Heinrich, Juan C.; Poirier, David R.

1992-01-01

A mathematical model of solidification is presented which simulates the formation of segregation models known as 'freckles' during directional solidification of binary alloys. The growth of the two-phase or dendritic zone is calculated by solving the coupled equations of momentum, energy, and solute transport, as well as maintaining the thermodynamic constraints dictated by the phase diagram of the alloy. Calculations for lead-tin alloys show that the thermosolutal convection in the dendritic zone during solidification can produce heavily localized inhomogeneities in the composition of the final alloy.

Modelling directional solidification

NASA Technical Reports Server (NTRS)

Wilcox, William R.

1987-01-01

An improved understanding of the phenomena of importance to directional solidification is attempted to enable explanation and prediction of differences in behavior between solidification on Earth and in space. Emphasis is now on experimentally determining the influence of convection and freezing rate fluctuations on compositional homogeneity and crystalline perfection. A correlation is sought between heater temperature profiles, buoyancy-driven convection, and doping inhomogeneities using naphthalene doped with anthracene. The influence of spin-up/spin-down is determined on compositional homogeneity and microstructure of indium gallium antimonide. The effect is determined of imposed melting - freezing cycles on indium gallium antimonide. The mechanism behind the increase of grain size caused by using spin-up/spin-down in directional solidification of mercury cadimum telluride is sought.

In Situ Monitoring of Crystal Growth Using MEPHISTO, Mission STS 87-Program USMP-4: Experimental Analysis

NASA Technical Reports Server (NTRS)

Abbaschian, Reza; Chen, F.; Mileham, J. R.; deGroh, H., III; Timchenko, V.; Leonardi, E.; deVahlDavis, G.; Coriell, S.; Cambon, G.

1999-01-01

This report summarizes the results of the In situ Monitoring of Crystal Growth Using MEPHISTO (Material por l'Etude des Phenomenes Interessant de la Solidification sur Terre et en Orbite) experiment on USMP-4. The report includes microstructural and compositional data obtained during the first year of the post flight analysis, as well as numerical simulation of the flight experiment. Additional analyses are being continued and will be reported in the near future. The experiments utilized MEPHISTO hardware to study the solidification and melting behavior of bismuth alloyed with 1 at% tin. The experiments involved repeated melting and solidification of three samples, each approximately 90 cm long and 6mm in diameter. Half of each sample also included a 2 mm. diameter growth capillary, to assist in the formation of single grain inside. One sample provided the Seebeck voltage generated during melting and freezing processes. Another one provided temperature data and Peltier pulsed demarcation of the interface shape for post flight analysis. The third sample provided resistance and velocity measurements, as well as additional thermal data. The third sample was also quenched at the end of the mission to preserve the interface composition for post flight determination. A total of more than 45cm of directionally solidified alloy were directionally solidified at the end of the flight for post mission structural and compositional characterization. Metallurgical analysis of the samples has shown that the interfacial kinetics play a key role in controlling the morphological stability of faceted alloys. Substantial differences were observed in the Seebeck signal between the ground-based experiments and the space-based experiments. The temperature gradient in the liquid for the ground-based experiments was also significantly lower than the temperature gradient in the liquid for the space-based experiments. Both of these observations indicate significant influence of liquid convection for the ground-based experiments.

Experimental study of directional solidification of aqueous ammonium chloride solution

NASA Technical Reports Server (NTRS)

Chen, C. F.; Chen, Falin

1991-01-01

Directional solidification experiments have been carried out using the analog casting system of NH4Cl-H2O solution by cooling it from below with a constant-temperature surface ranging from -31.5 C to +11.9 C. The NH4Cl concentration was 26 percent in all solutions, with a liquidus temperature of 15 C. It was found that finger convection occurred in the fluid region just above the mushy layer in all experiments. Plume convection with associated chimneys in the mush occurred in experiments with bottom temperatures as high as +11.0 C. However, when the bottom temperature was raised to +11.9 C, no plume convection was observed, although finger convection continued as usual. A method has been devised to determine the porosity of the mush by computed tomography. Using the mean value of the porosity across the mush layer and the permeability calculated by the Kozeny-Carman relationship, the critical solute Rayleigh number across the mush layer for onset of plume convection was estimated to be between 200 and 250.

Reproducible Crystal Growth Experiments in Microgravity Science Glovebox at the International Space Station (SUBSA Investigation)

NASA Technical Reports Server (NTRS)

Ostrogorsky, A.; Marin, C.; Volz, M. P.; Bonner, W. A.

2005-01-01

Solidification Using a Baffle in Sealed Ampoules (SUBSA) is the first investigation conducted in the Microgravity Science Glovebox (MSG) Facility at the International Space Station (ISS) Alpha. 8 single crystals of InSb, doped with Te and Zn, were directionally solidified in microgravity. The experiments were conducted in a furnace with a transparent gradient section, and a video camera, sending images to the earth. The real time images (i) helped seeding, (ii) allowed a direct measurement of the solidification rate. The post-flight characterization of the crystals includes: computed x-ray tomography, Secondary Ion Mass Spectroscopy (SIMS), Hall measurements, Atomic Absorption (AA), and 4 point probe analysis. For the first time in microgravity, several crystals having nearly identical initial transients were grown. Reproducible initial transients were obtained with Te-doped InSb. Furthermore, the diffusion controlled end-transient was demonstrated experimentally (SUBSA 02). From the initial transients, the diffusivity of Te and Zn in InSb was determined.

Containerless solidification of BiFeO3 oxide under microgravity

NASA Astrophysics Data System (ADS)

Yu, Jianding; Arai, Yasutomo; Koshikawa, Naokiyo; Ishikawa, Takehito; Yoda, Shinichi

1999-07-01

Containerless solidification of BiFeO3 oxide has been carried out under microgravity with Electrostatic Levitation Furnace (ELF) aboard on the sounding rocket (TR-IA). It is a first containerless experiment using ELF under microgravity for studying the solidification of oxide insulator material. Spherical BiFeO3 sample with diameter of 5mm was heated by two lasers in oxygen and nitrogen mixing atmosphere, and the sample position by electrostatic force under pinpoint model and free drift model. In order to compare the solidification behavior in microgravity with on ground, solidification experiments of BiFeO3 in crucible and drop tube were carried out. In crucible experiment, it was very difficult to get single BiFeO3 phase, because segregation of Fe2O3 occured very fast and easily. In drop tube experiment, fine homogeneous BiFeO3 microstructure was obtained in a droplet about 300 μm. It implies that containerless processing can promote the phase selection in solidification. In microgravity experiment, because the heating temperature was lower than that of estimated, the sample was heated into Fe2O3+liquid phase region. Fe2O3 single crystal grew on the surface of the spherical sample, whose sample was clearly different from that observed in ground experiments.

Thermoelectric magnetohydrodynamic effects on the crystal growth rate of undercooled Ni dendrites

NASA Astrophysics Data System (ADS)

Kao, A.; Gao, J.; Pericleous, K.

2018-01-01

In the undercooled solidification of pure metals, the dendrite tip velocity has been shown experimentally to have a strong dependence on the intensity of an external magnetic field, exhibiting several maxima and minima. In the experiments conducted in China, the undercooled solidification dynamics of pure Ni was studied using the glass fluxing method. Visual recordings of the progress of solidification are compared at different static fields up to 6 T. The introduction of microscopic convective transport through thermoelectric magnetohydrodynamics is a promising explanation for the observed changes of tip velocities. To address this problem, a purpose-built numerical code was used to solve the coupled equations representing the magnetohydrodynamic, thermal and solidification mechanisms. The underlying phenomena can be attributed to two competing flow fields, which were generated by orthogonal components of the magnetic field, parallel and transverse to the direction of growth. Their effects are either intensified or damped out with increasing magnetic field intensity, leading to the observed behaviour of the tip velocity. The results obtained reflect well the experimental findings. This article is part of the theme issue `From atomistic interfaces to dendritic patterns'.

Directional solidification of Al2-Cu-Al and Al3-Ni-Al eutectics during TEXUS rocket flight

NASA Technical Reports Server (NTRS)

Favier, J. J.; Degoer, J.

1984-01-01

One lamellar eutectic sample and one fiber-like eutectic sample were solidified directionally during the TEXUS-6 rocket flight. The microstructures and the results of the thermal analysis, obtained from the temperatures recorded on the cartridge skin, are compared. No appreciable modifications of the regularity of the eutectic structures were observed by passing from 1 g to 0.0001 g in these experiments. No steady state growth conditions were achieved in these experiments.

KSC-97PC1379

NASA Image and Video Library

1997-09-08

United States Microgravity Payload-4 (USMP-4) experiments are prepared to be flown on Space Shuttle mission STS-87 in the Space Station Processing Facility at Kennedy Space Center (KSC). Seen in the foreground at right is the Isothermal Dendritic Growth Experiment (IDGE), which will be used to study the dendritic solidification of molten materials in the microgravity environment. The metallic breadbox-like structure behind the IDGE is the Confined Helium Experiment (CHeX) that will study one of the basic influences on the behavior and properties of materials by using liquid helium confined between solid surfaces and microgravity. The large white vertical cylinder at left is the Advanced Automated Directional Solidification Furnace (AADSF) and the horizontal tube behind it is MEPHISTO, the French acronym for a cooperative American-French investigation of the fundamentals of crystal growth. Just below the left end of MEPHISTO is the Space Acceleration Measurement System, or SAMS, which measures the microgravity conditions in which the experiments are conducted. All of these experiments are scheduled for launch aboard STS-87 on Nov. 19 from KSC

Design of a High Thermal Gradient Bridgman Furnace

NASA Technical Reports Server (NTRS)

LeCroy, J. E.; Popok, D. P.

1994-01-01

The Advanced Automated Directional Solidification Furnace (AADSF) is a Bridgman-Stockbarger microgravity processing facility, designed and manifested to first fly aboard the second United States Microgravity Payload (USMP-2) Space Shuttle mission. The AADSF was principally designed to produce high axial thermal gradients, and is particularly suitable for metals solidification experiments, including non-dilute alloys. To accommodate a wider range of experimental conditions, the AADSF is equipped with a reconfigurable gradient zone. The overall design of the AADSF and the relationship between gradient zone design and furnace performance are described. Parametric thermal analysis was performed and used to select gradient zone design features that fulfill the high thermal gradient requirements of the USMP-2 experiment. The thermal model and analytical procedure, and parametric results leading to the first flight gradient zone configuration, are presented. Performance for the USMP-2 flight experiment is also predicted, and analysis results are compared to test data.

Distribution Behavior of B and P during Al-Si Melt Directional Solidification with Open-Ended Crucible

NASA Astrophysics Data System (ADS)

Bai, Xiaolong; Ban, Boyuan; Li, Jingwei; Peng, Zhijian; Chen, Jian

2018-03-01

Distribution behavior of B and P during directional solidification of Al-20Si, Al-30Si and Al-40Si alloys has been investigated. Macrostructure of the Al-Si alloy ingots and concentration profile of elements B and P reveal that the elements segregate to eutectic Al-Si melt during growth of primary Si flakes, and P gradually segregates to the top of the ingots during directional solidification. An apparent segregation coefficient, ka, is introduced to describe the segregation behavior of B and P between the primary Si and the Al-Si melt and compared with thermodynamic theoretical equilibrium coefficients. The apparent segregation coefficients of B and P decrease with increase of solidification temperature.

Effect of Marangoni Convection Generated by Voids on Segregation During Low-G and 1-G Solidification

NASA Technical Reports Server (NTRS)

Kassemi, M.; Fripp, A.; Rashidnia, N.; deGroh, H.

1999-01-01

Solidification experiments, especially microgravity solidification experiments are often hampered by the evolution of unwanted voids or bubbles in the melt. Although these voids and/or bubbles are highly undesirable, there are currently no effective means of preventing their formation or eliminating their adverse effects, particularly, during low-g experiments. Marangoni Convection caused by these voids can drastically change the transport processes in the melt and, therefore, introduce enormous difficulties in interpreting the results of the space investigations. Recent microgravity experiments by Matthiesen, Andrews, and Fripp are all good examples of how the presence of voids and bubbles affect the outcome of costly space experiments and significantly increase the level of difficulty in interpreting their results. In this work we examine mixing caused by Marangoni convection generated by voids and bubbles in the melt during both 1-g and low-g solidification experiments. The objective of the research is to perform a detailed and comprehensive combined numerical-experimental study of Marangoni convection caused by voids during the solidification process and to show how it can affect segregation and growth conditions by modifying the flow, temperature, and species concentration fields in the melt. While Marangoni convection generated by bubbles and voids in the melt can lead to rapid mixing that would negate the benefits of microgravity processing, it could be exploited in some terrestrial processing to ensure effective communication between a melt/solid interface and a gas phase stoichiometry control zone. Thus we hope that this study will not only aid us in interpreting the results of microgravity solidification experiments hampered by voids and bubbles but to guide us in devising possible means of minimizing the adverse effects of Marangoni convection in future space experiments or of exploiting its beneficial mixing features in ground-based solidification.

Convection and Solidification with Applications to Crystal Growth

NASA Technical Reports Server (NTRS)

DeVahl Davis, Graham

1994-01-01

An outline is given of research on the directional solidification of a liquid, and of the effects of natural convection thereon. Three problems which have been studied are described. Finally, current work on solidification in microgravity conditions is discussed.

Simulation of Channel Segregation During Directional Solidification of In—75 wt pct Ga. Qualitative Comparison with In Situ Observations

NASA Astrophysics Data System (ADS)

Saad, Ali; Gandin, Charles-André; Bellet, Michel; Shevchenko, Natalia; Eckert, Sven

2015-11-01

Freckles are common defects in industrial casting. They result from thermosolutal convection due to buoyancy forces generated from density variations in the liquid. The present paper proposes a numerical analysis for the formation of channel segregation using the three-dimensional (3D) cellular automaton (CA)—finite element (FE) model. The model integrates kinetics laws for the nucleation and growth of a microstructure with the solution of the conservation equations for the casting, while introducing an intermediate modeling scale for a direct representation of the envelope of the dendritic grains. Directional solidification of a cuboid cell is studied. Its geometry, the alloy chosen as well as the process parameters are inspired from experimental observations recently reported in the literature. Snapshots of the convective pattern, the solute distribution, and the morphology of the growth front are qualitatively compared. Similitudes are found when considering the coupled 3D CAFE simulations. Limitations of the model to reach direct simulation of the experiments are discussed.

Stochastic modelling of microstructure formation in solidification processes

NASA Astrophysics Data System (ADS)

Nastac, Laurentiu; Stefanescu, Doru M.

1997-07-01

To relax many of the assumptions used in continuum approaches, a general stochastic model has been developed. The stochastic model can be used not only for an accurate description of the fraction of solid evolution, and therefore accurate cooling curves, but also for simulation of microstructure formation in castings. The advantage of using the stochastic approach is to give a time- and space-dependent description of solidification processes. Time- and space-dependent processes can also be described by partial differential equations. Unlike a differential formulation which, in most cases, has to be transformed into a difference equation and solved numerically, the stochastic approach is essentially a direct numerical algorithm. The stochastic model is comprehensive, since the competition between various phases is considered. Furthermore, grain impingement is directly included through the structure of the model. In the present research, all grain morphologies are simulated with this procedure. The relevance of the stochastic approach is that the simulated microstructures can be directly compared with microstructures obtained from experiments. The computer becomes a `dynamic metallographic microscope'. A comparison between deterministic and stochastic approaches has been performed. An important objective of this research was to answer the following general questions: (1) `Would fully deterministic approaches continue to be useful in solidification modelling?' and (2) `Would stochastic algorithms be capable of entirely replacing purely deterministic models?'

Novel Directional Solidification Processing of Hypermonotectic Alloys

NASA Technical Reports Server (NTRS)

Grugel, Richard N.

1999-01-01

Gravity driven separation precludes uniform microstructural development during controlled directional solidification (DS) processing of hypermonotectic alloys. It is well established that liquid/liquid suspensions, in which the respective components are immiscible and have significant density differences, can be established and maintained by utilizing ultrasound. A historical introduction to this work is presented with the intent of establishing the basis for applying the phenomena to promote microstructural uniformity during controlled directional solidification processing of immiscible mixtures. Experimental work based on transparent organics, as well as salt systems, will be presented in view of the processing parameters.

Solidification effects on sill formation: An experimental approach

NASA Astrophysics Data System (ADS)

Chanceaux, L.; Menand, T.

2014-10-01

Sills represent a major mechanism for constructing continental Earth's crust because these intrusions can amalgamate and form magma reservoirs and plutons. As a result, numerous field, laboratory and numerical studies have investigated the conditions that lead to sill emplacement. However, all previous studies have neglected the potential effect magma solidification could have on sill formation. The effects of solidification on the formation of sills are studied and quantified with scaled analogue laboratory experiments. The experiments presented here involved the injection of hot vegetable oil (a magma analogue) which solidified during its propagation as a dyke in a colder and layered solid of gelatine (a host rock analogue). The gelatine solid had two layers of different stiffness, to create a priori favourable conditions to form sills. Several behaviours were observed depending on the injection temperature and the injection rate: no intrusions (extreme solidification effects), dykes stopping at the interface (high solidification effects), sills (moderate solidification effects), and dykes passing through the interface (low solidification effects). All these results can be explained quantitatively as a function of a dimensionless temperature θ, which describes the experimental thermal conditions, and a dimensionless flux ϕ, which describes their dynamical conditions. The experiments reveal that sills can only form within a restricted domain of the (θ , ϕ) parameter space. These experiments demonstrate that contrary to isothermal experiments where cooling could not affect sill formation, the presence of an interface that would be a priori mechanically favourable is not a sufficient condition for sill formation; solidification effects restrict sill formation. The results are consistent with field observations and provide a means to explain why some dykes form sills when others do not under seemingly similar geological conditions.

Simulation Computation of 430 Ferritic Stainless Steel Solidification

NASA Astrophysics Data System (ADS)

Pang, Ruipeng; Li, Changrong; Wang, Fuming; Hu, Lifu

The solidification structure of 430 ferritic stainless steel has been calculated in the solidification process by using 3D-CAFE model under the condition of water cooling. The calculated results consistent with those obtained from experiment. Under watercooling condition, the solidification structure consists of chilled layer, columnar grain zone, transition zone and equiaxed grain zone.

Ukrainian Program for Material Science in Microgravity

NASA Astrophysics Data System (ADS)

Fedorov, Oleg

Ukrainian Program for Material Sciences in Microgravity O.P. Fedorov, Space Research Insti-tute of NASU -NSAU, Kyiv, The aim of the report is to present previous and current approach of Ukrainian research society to the prospect of material sciences in microgravity. This approach is based on analysis of Ukrainian program of research in microgravity, preparation of Russian -Ukrainian experiments on Russian segment of ISS and development of new Ukrainian strategy of space activity for the years 2010-2030. Two parts of issues are discussed: (i) the evolution of our views on the priorities in microgravity research (ii) current experiments under preparation and important ground-based results. item1 The concept of "space industrialization" and relevant efforts in Soviet and post -Soviet Ukrainian research institutions are reviewed. The main topics are: melt supercooling, crystal growing, testing of materials, electric welding and study of near-Earth environment. The anticipated and current results are compared. item 2. The main experiments in the framework of Ukrainian-Russian Research Program for Russian Segment of ISS are reviewed. Flight installations under development and ground-based results of the experiments on directional solidification, heat pipes, tribological testing, biocorrosion study is presented. Ground-based experiments and theoretical study of directional solidification of transparent alloys are reviewed as well as preparation of MORPHOS installation for study of succinonitrile -acetone in microgravity.

Preliminary in situ and real-time study of directional solidification of metallic alloys by x-ray imaging techniques

NASA Astrophysics Data System (ADS)

Nguyen Thi, H.; Jamgotchian, H.; Gastaldi, J.; Härtwig, J.; Schenk, T.; Klein, H.; Billia, B.; Baruchel, J.; Dabo, Y.

2003-05-01

During directional solidification of a binary alloy, the solid-liquid interface exhibits a variety of patterns that are due to the Mullins-Sekerka instability and governed by the growth conditions. It is well known that properties of the grown material are largely controlled by the microstructures left in the solid during processing. Thus, a precise mastering of the solidification is essential to tailor products in a reproducible fashion to a specified quality. One major difficulty for this study is the real-time and in situ observation of the interface, especially for metallic alloys. A possibility is to use an intense and coherent third generation x-ray beam. By combining different x-ray imaging techniques (absorption/phase contrast radiography and diffraction topography), we have studied the directional melting and solidification of aluminium-based alloys. The preliminary results show the great potential of these techniques for the study of the coupling between stress effects and microstructure formation in solidification processing.

Direct chill casting of aluminium alloys under electromagnetic interaction by permanent magnet assembly

NASA Astrophysics Data System (ADS)

Bojarevičs, Andris; Kaldre, Imants; Milgrāvis, Mikus; Beinerts, Toms

2018-05-01

Direct chill casting is one of the methods used in industry to obtain good microstructure and properties of aluminium alloys. Nevertheless, for some alloys grain structure is not optimal. In this study, we offer the use of electromagnetic interaction to modify melt convection near the solidification interface. Solidification under various electromagnetic interactions has been widely studied, but usually at low solidification velocity and high thermal gradient. This type of interaction may succeed fragmentation of dendrite arms and transport of solidification nuclei thus leading to improved material structure and properties. Realization of experimental small-scale crystallizer and electromagnetic system has been described in this article.

Solidification kinetics of a Cu-Zr alloy: ground-based and microgravity experiments

NASA Astrophysics Data System (ADS)

Galenko, P. K.; Hanke, R.; Paul, P.; Koch, S.; Rettenmayr, M.; Gegner, J.; Herlach, D. M.; Dreier, W.; Kharanzhevski, E. V.

2017-04-01

Experimental and theoretical results obtained in the MULTIPHAS-project (ESA-European Space Agency and DLR-German Aerospace Center) are critically discussed regarding solidification kinetics of congruently melting and glass forming Cu50Zr50 alloy samples. The samples are investigated during solidification using a containerless technique in the Electromagnetic Levitation Facility [1]. Applying elaborated methodologies for ground-based and microgravity experimental investigations [2], the kinetics of primary dendritic solidification is quantitatively evaluated. Electromagnetic Levitator in microgravity (parabolic flights and on board of the International Space Station) and Electrostatic Levitator on Ground are employed. The solidification kinetics is determined using a high-speed camera and applying two evaluation methods: “Frame by Frame” (FFM) and “First Frame - Last Frame” (FLM). In the theoretical interpretation of the solidification experiments, special attention is given to the behavior of the cluster structure in Cu50Zr50 samples with the increase of undercooling. Experimental results on solidification kinetics are interpreted using a theoretical model of diffusion controlled dendrite growth.

Materials science on parabolic aircraft: The FY 1987-1989 KC-135 microgravity test program

NASA Technical Reports Server (NTRS)

Curreri, Peter A. (Editor)

1993-01-01

This document covers research results from the KC-135 Materials Science Program managed by MSFC for the period FY87 through FY89. It follows the previous NASA Technical Memorandum for FY84-86 published in August 1988. This volume contains over 30 reports grouped into eight subject areas covering acceleration levels, space flight hardware, transport and interfacial studies, thermodynamics, containerless processing, welding, melt/crucible interactions, and directional solidification. The KC-135 materials science experiments during FY87-89 accomplished direct science, preparation for space flight experiments, and justification for new experiments in orbit.

Analysis and calculation of macrosegregation in a casting ingot. MPS solidification model. Volume 3: Operating manual

NASA Technical Reports Server (NTRS)

Maples, A. L.

1980-01-01

The operation of solidification model 1 is described. Model 1 calculates the macrosegregation in a rectangular ingot of a binary alloy as a result of horizontal axisymmetric bidirectional solidification. The calculation is restricted to steady-state solidification; there is no variation in final local average composition in the direction of isotherm movement. The physics of the model are given.

Directional Solidification and Mechanical Properties of NiAl-NiAlTa Alloys

NASA Technical Reports Server (NTRS)

Johnson, D. R.; Chen, X. F.; Oliver, B. F.; Noebe, R. D.; Whittenberger, J. D.

1995-01-01

Directional solidification of eutectic alloys is a promising technique for producing in-situ composite materials exhibiting a balance of properties. Consequently, the microstructure, creep strength and fracture toughness of directionally solidified NiAl-NiAlTa alloys were investigated. Directional solidification was performed by containerless processing techniques to minimize alloy contamination. The eutectic composition was found to be NiAl-15.5 at% Ta and well-aligned microstructures were produced at this composition. A near-eutectic alloy of NiAl-14.5Ta was also investigated. Directional solidification of the near-eutectic composition resulted in microstructures consisting of NiAl dendrites surrounded by aligned eutectic regions. The off-eutectic alloy exhibited promising compressive creep strengths compared to other NiAl-based intermetallics, while preliminary testing indicated that the eutectic alloy was competitive with Ni-base single crystal superalloys. The room temperature toughness of these two-phase alloys was similar to that of polycrystalline NiAl even with the presence of the brittle Laves phase NiAlTa.

Preliminary flight results from the second U.S. Microgravity Payload (USMP-2)

NASA Technical Reports Server (NTRS)

Curreri, Peter; Reiss, Donald

1994-01-01

The second U.S. Microgravity Payload (USMP-2) was flown on the Space Shuttle in March 1994. It carried four major microgravity experiments plus a sophisticated accelerometer system to record the microgravity environment during USMP-2 operations. The USMP program is designed to accommodate experiments requiring extensive resources short of a full Spacelab mission, and the experiments are remotely operated and monitored. Results are reviewed from the four experiments: the Advanced Automated Directional Solidification Facility (AADSF), the Isothermal Dendrite Growth Experiment (IDGE), the Materiel por Etude des Phenomenes Interessant la Soldification sur Terre et en Orbite (MEPHISTO), and the Critical Fluid Light Scattering Experiment (Zeno). AASDF grew what is expected to be the largest steady-state sample ever of HgCdTe during 240 hours of operation. IDGE provided 60 growth cycles over a wide range of supercooling conditions studying the dendritic solidification of succinonitrile. MEPHISTO achieved 55 melt-solidify cycles and grew over 1 m of Bi/Sn alloy. Zeno located the critical point temperature for liquid Xe to 0.00001 K. IDGE and Zeno also provided the most extensive demonstrations to date of telescience.

Effects of Traveling Magnetic Field on Dynamics of Solidification

NASA Technical Reports Server (NTRS)

Mazuruk, Konstantin; Grugel, Richard; Motakef, Shariar

2001-01-01

TMF is based on imposing a controlled phase-shift in a train of electromagnets, forming a stack. Thus, the induced magnetic field can be considered to be travelling along the axis of the stack. The coupling of this traveling wave with an electrically conducting fluid results in a basic flow in a form of a single axisymmetric roll. The magnitude and direction of this flow can be remotely controlled. Furthermore, it is possible to localize the effect of this force field though activating only a number of the magnets. This force field generated in the fluid can, in principle, be used to control and modify convection in the molten material. For example, it can be used to enhance convective mixing in the melt, and thereby modify the interface shape, and macrosegregation. Alternatively, it can be used to counteract thermal and/or solutal buoyancy forces. High frequency TMF can be used in containerless processing techniques, such as float zoning, to affect the very edge of the fluid so that Marangoni flow can be counter balanced. The proposed program consists of basic fundamentals and applications. Our goal in conducting the following experiments and analyses is to establish the validity of TMF as a new tool for solidification processes. Due to its low power consumption and simplicity of design, this tool may find wide spread use in a variety of space experiments. The proposed ground based experiments are intended to establish the advantages and limitations of employing this technique. In the fundamentals component of the proposed program, we will use theoretical tools and experiments with mercury to establish the fundamental aspects of TMF-induced convection through a detailed comparison of theoretical predictions and experimental measurements of flow field. In this work, we will conduct a detailed parametric study involving the effects of magnetic field strength, frequency, wave vector, and the fluid geometry. The applications component of this work will be focused on investigating the effect of TMF on the following solidification and pre-directional solidification processes: (1) Bridgman growth of Ga:Ge with the goal of counteracting the buoyancy-driven convection; (2) Mixing of Pb-Ga and Pb-Sn alloys with the aim of initiating and maintaining a uniform melt prior to solidification processing; and (3) Float Zone growth with the aim of identifying, through simulations and model experiments, conditions needed to counteract Marangoni flow in a microgravity environment. The proposed research has strong relevance to microgravity research and the objectives of the NRA. TMF can provide a unique and accurate mechanism for generation and control of desirable flow patterns for microgravity research. These attributes have significant relevance to 1) Alloy mixing prior to solidification in a microgravity environment. TMF can provide this mixing with a low level of power consumption; (2) TMF can offset the deleterious effects of Marangoni convection in microgravity containerless processing. Thus, TMF can be instrumental in further understanding this phenomena; (3) Generation of controlled flows will allow the investigation of the effect of these flows on growth morphology and growth kinetics; and (4) On Earth, TMF has the potential to significantly counter-balance thermosolutal convection, thereby creating conditions similar to those obtained in microgravity. Once demonstrated, this new tool for use in solidification has the strong potential to find applications in a host of microgravity material research projects.

Preparation of silicon target material by adding Al-B master alloy in directional solidification

NASA Astrophysics Data System (ADS)

Li, Pengting; Wang, Kai; Ren, Shiqiang; Jiang, Dachuan; Tan, Yi

2017-03-01

The silicon target material was prepared by adding Al-6B master alloy in directional solidification. The microstructure was characterized and the resistivity was studied in this work. The results showed that the purity of the silicon target material was more than 99.999% (5N). The resistivity was ranges from 0.002 to 0.030 Ω·cm along the ingot height. It was revealed that the particles of AlB2 in Al-6B master alloy would react spontaneously and generate clusters of [B] and [Al] in molten silicon at 1723 K. After directional solidification, the content of B and Al were increasing gradually with the increase of solidified fraction. The measured values of B were in good agreement with the curve of the Scheil equation below 80% of the ingot height. The mean concentration of B was about 17.20 ppmw and the mean concentration of Al was about 8.07 ppmw after directional solidification. The measured values of Al were fitting well with the curve of values which the effective segregation coefficient was 0.00378. It was observed that B co-doped Al in directional solidification polysilicon could regulate resistivity mutually. This work provides the theoretical basis and technical support for industrial production of the silicon target material.

Columnar-to-Equiaxed Transition and Equiaxed Grain Alignment in Directionally Solidified Ni3Al Alloy Under an Axial Magnetic Field

NASA Astrophysics Data System (ADS)

Liu, Huan; Xuan, Weidong; Xie, Xinliang; Li, Chuanjun; Wang, Jiang; Yu, Jianbo; Li, Xi; Zhong, Yunbo; Ren, Zhongming

2017-09-01

The effect of an axial magnetic field on the solidification structure in directionally solidified Ni-21.5Al-0.4Zr-0.1B (at. pct) alloy was investigated. The experimental results indicated that the application of a high magnetic field caused the deformation of dendrites and the occurrence of columnar-to-equiaxed transition (CET). The magnetic field tended to orient the 〈001〉 crystal direction of the equiaxed grains along the magnetic field direction. The bulk solidification experiment under a high magnetic field showed that the crystal exhibited magnetic crystalline anisotropy. Further, the thermoelectric (TE) magnetic force and TE magnetic convention were analyzed by three-dimensional (3-D) numerical simulations. The results showed that the maximum value of TE magnetic force localized in the vicinity of the secondary dendrite arm root, which should be responsible for the dendrite break and CET. Based on the high-temperature creep mechanism, a simple model was proposed to describe the magnetic field intensity needed for CET: B ≥ kG^{ - 1.5} R^{1.25} . The model is in good agreement with the experiment results. The experimental results should be attributed to the combined action of TE magnetic effects and the magnetic moment.

Directional Solidification and Liquidus Projection of the Sn-Co-Cu System

NASA Astrophysics Data System (ADS)

Chen, Sinn-Wen; Chang, Jui-Shen; Pan, Kevin; Hsu, Chia-Ming; Hsu, Che-Wei

2013-04-01

This study investigates the Sn-Co-Cu ternary system, which is of interest to the electronics industry. Ternary Sn-Co-Cu alloys were prepared, their as-solidified microstructures were examined, and their primary solidification phases were determined. The primary solidification phases observed were Cu, Co, Co3Sn2, CoSn, CoSn2, Cu6Sn5, Co3Sn2, γ, and β phases. Although there are ternary compounds reported in this ternary system, no ternary compound was found as the primary solidification phase. The directional solidification technique was applied when difficulties were encountered using the conventional quenching method to distinguish the primary solidification phases, such as Cu6Sn5, Cu3Sn, and γ phases. Of all the primary solidification phases, the Co3Sn2 and Co phases have the largest compositional regimes in which alloys display them as the primary solidification phases. There are four class II reactions and four class III reactions. The reactions with the highest and lowest reaction temperatures are both class III reactions, and are L + CoSn2 + Cu6Sn5 = CoSn3 at 621.5 K (348.3 °C) and L + Co3Sn2 + CoSn = Cu6Sn5 at 1157.8 K (884.6 °C), respectively.

Matching time and spatial scales of rapid solidification: dynamic TEM experiments coupled to CALPHAD-informed phase-field simulations

NASA Astrophysics Data System (ADS)

Perron, Aurelien; Roehling, John D.; Turchi, Patrice E. A.; Fattebert, Jean-Luc; McKeown, Joseph T.

2018-01-01

A combination of dynamic transmission electron microscopy (DTEM) experiments and CALPHAD-informed phase-field simulations was used to study rapid solidification in Cu-Ni thin-film alloys. Experiments—conducted in the DTEM—consisted of in situ laser melting and determination of the solidification kinetics by monitoring the solid-liquid interface and the overall microstructure evolution (time-resolved measurements) during the solidification process. Modelling of the Cu-Ni alloy microstructure evolution was based on a phase-field model that included realistic Gibbs energies and diffusion coefficients from the CALPHAD framework (thermodynamic and mobility databases). DTEM and post mortem experiments highlighted the formation of microsegregation-free columnar grains with interface velocities varying from ˜0.1 to ˜0.6 m s-1. After an ‘incubation’ time, the velocity of the planar solid-liquid interface accelerated until solidification was complete. In addition, a decrease of the temperature gradient induced a decrease in the interface velocity. The modelling strategy permitted the simulation (in 1D and 2D) of the solidification process from the initially diffusion-controlled to the nearly partitionless regimes. Finally, results of DTEM experiments and phase-field simulations (grain morphology, solute distribution, and solid-liquid interface velocity) were consistent at similar time (μs) and spatial scales (μm).

Matching time and spatial scales of rapid solidification: Dynamic TEM experiments coupled to CALPHAD-informed phase-field simulations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Perron, Aurelien; Roehling, John D.; Turchi, Patrice E. A.

A combination of dynamic transmission electron microscopy (DTEM) experiments and CALPHAD-informed phase-field simulations was used to study rapid solidification in Cu–Ni thin-film alloys. Experiments—conducted in the DTEM—consisted of in situ laser melting and determination of the solidification kinetics by monitoring the solid–liquid interface and the overall microstructure evolution (time-resolved measurements) during the solidification process. Modelling of the Cu–Ni alloy microstructure evolution was based on a phase-field model that included realistic Gibbs energies and diffusion coefficients from the CALPHAD framework (thermodynamic and mobility databases). DTEM and post mortem experiments highlighted the formation of microsegregation-free columnar grains with interface velocities varying frommore » ~0.1 to ~0.6 m s –1. After an 'incubation' time, the velocity of the planar solid–liquid interface accelerated until solidification was complete. In addition, a decrease of the temperature gradient induced a decrease in the interface velocity. The modelling strategy permitted the simulation (in 1D and 2D) of the solidification process from the initially diffusion-controlled to the nearly partitionless regimes. Lastly, results of DTEM experiments and phase-field simulations (grain morphology, solute distribution, and solid–liquid interface velocity) were consistent at similar time (μs) and spatial scales (μm).« less

Matching time and spatial scales of rapid solidification: Dynamic TEM experiments coupled to CALPHAD-informed phase-field simulations

DOE PAGES

Perron, Aurelien; Roehling, John D.; Turchi, Patrice E. A.; ...

2017-12-05

A combination of dynamic transmission electron microscopy (DTEM) experiments and CALPHAD-informed phase-field simulations was used to study rapid solidification in Cu–Ni thin-film alloys. Experiments—conducted in the DTEM—consisted of in situ laser melting and determination of the solidification kinetics by monitoring the solid–liquid interface and the overall microstructure evolution (time-resolved measurements) during the solidification process. Modelling of the Cu–Ni alloy microstructure evolution was based on a phase-field model that included realistic Gibbs energies and diffusion coefficients from the CALPHAD framework (thermodynamic and mobility databases). DTEM and post mortem experiments highlighted the formation of microsegregation-free columnar grains with interface velocities varying frommore » ~0.1 to ~0.6 m s –1. After an 'incubation' time, the velocity of the planar solid–liquid interface accelerated until solidification was complete. In addition, a decrease of the temperature gradient induced a decrease in the interface velocity. The modelling strategy permitted the simulation (in 1D and 2D) of the solidification process from the initially diffusion-controlled to the nearly partitionless regimes. Lastly, results of DTEM experiments and phase-field simulations (grain morphology, solute distribution, and solid–liquid interface velocity) were consistent at similar time (μs) and spatial scales (μm).« less

STS-75 Flight Day 1

NASA Technical Reports Server (NTRS)

1996-01-01

On this first day of the STS-75 mission, the flight crew, Cmdr. Andrew Allen, Pilot Scott Horowitz, Payload Cmdr. Franklin Chang-Diaz, Payload Specialist Umberto Guidoni (Italy), and Mission Specialists Jeffrey Hoffman, Maurizio Cheli (ESA) and Claude Nicollier (ESA), were shown performing pre-launch and launching activities. This international space mission's primary objective is the deployment of the Tethered Satellite System Reflight (TSS-1R) to a 12 mile length from the shuttle, a variety of experiments, and the satellite retrieval. These experiments include: Research on Orbital Plasma Electrodynamics (ROPE); TSS Deployer Core Equipment and Satellite Core Equipment (DCORE/SCORE); Research on Electrodynamic Tether Effects (RETE); Magnetic Field Experiments for TSS Missions (TEMAG); Shuttle Electrodynamic Tether Systems (SETS); Shuttle Potential and Return Electron Experiment (SPREE); Tether Optical Phenomena Experiment (TOP); and Observations at the Earth's Surface of Electromagnetic Emissions by TSS (OESSE). The mission's secondary objectives were those experiments found in the United States Microgravity Payload-3 (USMP-3), which include: Advanced Automated Directional Solidification Furnace (AADSF); Material pour l'Etude des Phenomenes Interessant la Solidification sur Terre et en Orbite (MEPHISTO); Space Acceleration Measurement System (SAMS); Orbital Acceleration Research Experiment (OARE); Critical Fluid Scattering Experiment (ZENO); and Isothermal Dendritic Growth Experiment (IDGE).

KSC-97PC1380

NASA Image and Video Library

1997-09-08

United States Microgravity Payload-4 (USMP-4) experiments are prepared to be flown on Space Shuttle mission STS-87 in the Space Station Processing Facility at Kennedy Space Center (KSC). Seen at right in the circular white cover is the Isothermal Dendritic Growth Experiment (IDGE), which will be used to study the dendritic solidification of molten materials in the microgravity environment. The large white vertical cylinder in the center of the photo is the Advanced Automated Directional Solidification Furnace (AADSF) and the horizontal tube to the left of it is MEPHISTO, a French acronym for a cooperative American-French investigation of the fundamentals of crystal growth. Just below MEPHISTO is the Space Acceleration Measurement System, or SAMS, which measures the microgravity conditions in which the experiments are conducted. The The metallic breadbox-like structure behind the AADSF is the Confined Helium Experiment (CHeX) that will study one of the basic influences on the behavior and properties of materials by using liquid helium confined between solid surfaces and microgravity. All of these experiments are scheduled for launch aboard STS-87 on Nov. 19 from KSC

Materials for the Study of Interesting Phenomena of Solidification on Earth and in Orbit (MEPHISTO)

NASA Technical Reports Server (NTRS)

1987-01-01

The MEPHISTO experiment is a cooperative American and French investigation of the fundamentals of crystal growth. MEPHISTO is a French-designed and built materials processing furnace. MEPHISTO experiments study solidation (also called freezing) during the growth cycle of liquid materials used for semiconductor crystals. Solidification is the process where materials change from liquid (melt) to solid. An example of the solidification process is water changing into ice.

A Chebyshev Collocation Method for Moving Boundaries, Heat Transfer, and Convection During Directional Solidification

NASA Technical Reports Server (NTRS)

Zhang, Yiqiang; Alexander, J. I. D.; Ouazzani, J.

1994-01-01

Free and moving boundary problems require the simultaneous solution of unknown field variables and the boundaries of the domains on which these variables are defined. There are many technologically important processes that lead to moving boundary problems associated with fluid surfaces and solid-fluid boundaries. These include crystal growth, metal alloy and glass solidification, melting and name propagation. The directional solidification of semi-conductor crystals by the Bridgman-Stockbarger method is a typical example of such a complex process. A numerical model of this growth method must solve the appropriate heat, mass and momentum transfer equations and determine the location of the melt-solid interface. In this work, a Chebyshev pseudospectra collocation method is adapted to the problem of directional solidification. Implementation involves a solution algorithm that combines domain decomposition, finite-difference preconditioned conjugate minimum residual method and a Picard type iterative scheme.

Effects of Space Environment on Flow and Concentration During Directional Solidification

NASA Technical Reports Server (NTRS)

Benjapiyaporn, C.; Timchenko, V.; Leonardi, E.; deVahlDavis, G.; deGroh, H. C., III

2000-01-01

A study of directional solidification of a weak binary alloy (specifically, Bi - 1 at% Sn) based on the fixed grid single domain approach is being undertaken. The enthalpy method is used to solve for the temperature field over the computational domain including both the solid and liquid phases; latent heat evolution is treated with the aid of an effective specific heat coefficient. A source term accounting for the release of solute into the liquid during solidification has been incorporated into the solute transport equation. The vorticity-stream function formulation is used to describe thermosolutal convection in the liquid region. In this paper we numerically investigate the effects of g-jitter on directional solidification. A background gravity of 1 micro-g has been assumed, and new results for the effects of periodic disturbances over a range of amplitudes and frequencies on solute field and segregation have been presented.

Microstructure and property of directionally solidified Ni-Si hypereutectic alloy

NASA Astrophysics Data System (ADS)

Cui, Chunjuan; Tian, Lulu; Zhang, Jun; Yu, Shengnan; Liu, Lin; Fu, Hengzhi

2016-03-01

This paper investigates the influence of the solidification rate on the microstructure, solid/liquid interface, and micro-hardness of the directionally solidified Ni-Si hypereutectic alloy. Microstructure of the Ni-Si hypereutectic alloy is refined with the increase of the solidification rate. The Ni-Si hypereutectic composite is mainly composed of α-Ni matrix, Ni-Ni3Si eutectic phase, and metastable Ni31Si12 phase. The solid/liquid interface always keeps planar interface no matter how high the solidification rate is increased. This is proved by the calculation in terms of M-S interface stability criterion. Moreover, the Ni-Si hypereutectic composites present higher micro-hardness as compared with that of the pure Ni3Si compound. This is caused by the formation of the metastable Ni31Si12 phase and NiSi phase during the directional solidification process.

Microstructural development and segregation effects in directionally solidified nickel-based superalloy PWA 1484

NASA Astrophysics Data System (ADS)

Li, Lichun

2002-09-01

These studies were performed to investigate the effects of thermal gradient (G) and growth velocity (V) on the microstructure development and solidification behavior of directionally solidified nickel-based superalloy PWA 1484. Directional solidification (DS) experiments were conducted using a Bridgman crystal growth facility. The solidification velocity ranged from 0.00005 to 0.01 cm/sec and thermal gradients ranged from 12 to 108°C/cm. The as-cast microstructures of DS samples were characterized by using conventional metallography; chemical composition and segregation of directionally solidified samples were analyzed with energy dispersive spectroscopy in SEM. A range of aligned solidification microstructures is exhibited by the alloy when examined as-cast at room temperature: dendrites, flanged cells, cells. The microstructure transitions from cellular to dendritic as the growth velocity increases. The experimental data for PWA1484 exhibits excellent agreement with the well-known exponential equation (lambda1 ∝ G -1/2V-1/4). However, the constant of proportionality is different depending upon the solidification microstructure: (1) dendritic growth with secondary arms leads to a marked dependence of lambda1 on G-1/2 V-1/4; (2) flanged cellular growth with no secondary arms leads to much lower dependence of lambda 1 on G-1/2V -1/4. The primary dendritic arm spacing results were also compared to recent theoretical models. The model of Hunt and Lu and the model of Ma and Sahm provided excellent agreement at medium to high thermal gradients and a wide range of solidification velocities. The anomalous behavior of lambda 1 with high growth velocity V at low G is analyzed based on the samples' microstructures. Off-axis heat flows were shown to cause radial non-uniformity in the dendrite arm spacing data for low thermal gradients and large withdrawal velocities. Various precipitates including gamma', (gamma ' + gamma) eutectic pool or divorced eutectic gamma ', and metal carbides were characterized. Processing conditions (growth velocity V and thermal gradient G) exert significant influence on both morphology and size of precipitates present. Freckle defects were observed on the surface of nickel-based superalloy MM247 cylindrical samples but not on the surface of cylindrical PWA 1484 samples. The Rayleigh number (Ra) that represents liquid instability at the interface was evaluated for MM247 and PWA 1484 in terms of a recently proposed theoretical equation. The effects of segregation, sloped solid/liquid interface and the morphology of dendritic/cellular trunks on the mushy zone convective flow and freckle formation are also discussed.

Analysis of Radial Segregation in Directionally Solidified Hg(0.89)Mn(0.11)Te

NASA Technical Reports Server (NTRS)

Price, M. W.; Scripa, R. N.; Szofran, F. R.; Motakef, S.; Hanson, B.

2003-01-01

Bridgman growth experiments were performed on Hg(0.89)Mn(0.11)Te (MMT) to determine the extent of radial Manganese segregation during directional solidification. MMT crystals were directionally solidified at rates of 0.09 and 0.18 p d s and in axial thermal gradients of 83 and 68"C/cm. Wavelength Dispersive Spectroscopy (WDS) and Fourier Transform Infra-Red (FTIR) analytical techniques were used to determine the radial homogeneity in all boules and the deflection of the solid-liquid interface (SLI) in two boules that were rapidly quenched after 5 to 6 cm of directional solidification. For all growth runs, the measured radial coinpositional variations were on the order of 0.01 molar percent MnTe in the steady state region of growth. Comparison of the measured radial compositional results of the crystals to predicted values in the diffusion-limited regime indicate a strong influence of convection near the solid-liquid interface. This conclusion is supported by the weak influence of the translation rates and axial thermal gradients utilized in this study upon radial compositional homogeneity.

The solidification velocity of nickel and titanium alloys

NASA Astrophysics Data System (ADS)

Altgilbers, Alex Sho

2002-09-01

The solidification velocity of several Ni-Ti, Ni-Sn, Ni-Si, Ti-Al and Ti-Ni alloys were measured as a function of undercooling. From these results, a model for alloy solidification was developed that can be used to predict the solidification velocity as a function of undercooling more accurately. During this investigation a phenomenon was observed in the solidification velocity that is a direct result of the addition of the various alloying elements to nickel and titanium. The additions of the alloying elements resulted in an additional solidification velocity plateau at intermediate undercoolings. Past work has shown a solidification velocity plateau at high undercoolings can be attributed to residual oxygen. It is shown that a logistic growth model is a more accurate model for predicting the solidification of alloys. Additionally, a numerical model is developed from simple description of the effect of solute on the solidification velocity, which utilizes a Boltzmann logistic function to predict the plateaus that occur at intermediate undercoolings.

On the role of convective motion during dendrite growth: Experiments under variable gravity, revised

NASA Technical Reports Server (NTRS)

Hallett, J.; Cho, N.; Harrison, K.; Lord, A.; Wedum, E.; Purcell, R.; Saunders, C. P. R.

1987-01-01

Experiments show the effect of self induced convection on individual dendrite growth in uniformly supercooled samples and solidification of the resulting mush under conditions of high and low g. Convection is visualized by a Schlieren optical system or a Mach Zender interferometer. For ice crystals growing from the vapor in air, a slight reduction in linear growth rate occur under low g. For ice crystals growing from NaCl solution, dendrite tip velocities are unchanged, but subsequent mush solidification is enhanced through drainage channels under higher g. By contrast, sodium sulfate decahydrate dendrites growing from solution produce convective plumes which lead to higher tip growth rate only as the crystal growth direction approaches that of gravity. Convective plumes are laminar for small crystals under conditions of these experiments; the rise velocity of such plumes is greater than individual vortex rings under identical conditions. Convection effects are only present in solution under a critical supercooling less than about 5 C for sodium sulfate and 2 C for ice in NaCl since at higher supercooling the crystallization velocity, proportional to the square of the supercooling, exceeds the convective velocity, proportional to the square root of the supercooling. The role of convective velocity in bulk solidification is to give a large scale flow which under extreme cases may lead to extensive secondary crystal production, which alters the resulting crystal texture of the completely solidified melt.

Three-dimensional phase-field simulations of directional solidification

NASA Astrophysics Data System (ADS)

Plapp, Mathis

2007-05-01

The phase-field method has become the method of choice for simulating microstructural pattern formation during solidification. One of its main advantages is that time-dependent three-dimensional simulations become feasible, which makes it possible to address long-standing questions of pattern stability and pattern selection. Here, a brief introduction to the phase-field model and its implementation is given, and its capabilities are illustrated by examples taken from the directional solidification of binary alloys. In particular, the morphological stability of hexagonal cellular arrays and of eutectic lamellar patterns is investigated.

Nature of solidification of nanoconfined organic liquid layers.

PubMed

Lang, X Y; Zhu, Y F; Jiang, Q

2007-01-30

A simple model is established for solidification of a nanoconfined liquid under nonequilibrium conditions. In terms of this model, the nature of solidification is the conjunct finite size and interface effects, which is directly related to the cooling rate or the relaxation time of the undercooled liquid. The model predictions are consistent with available experimental results.

Growth of Compound Semiconductors in a Low Gravity Environment: Microgravity Growth of PbSnTe

NASA Technical Reports Server (NTRS)

Fripp, A. L.; Debnam, W. J.; Rosch, W. R.; Baker, N. R.; Narayanan, R.

1999-01-01

The growth of the alloy compound semiconductor lead tin telluride (PbSnTe) was chosen for a microgravity flight experiment in the Advanced Automated Directional Solidification Furnace (AADSF), on the United States Microgravity Payload-3 (USNP-3) in February, 1996 and on USNW- 4 in November, 1997. The objective of these experiments was to determine the effect of the reduction in convection, during the growth process, brought about by the microgravity environment. The properties of devices made from PbSnTe, an alloy of PbTe and SnTe, are dependent on the ratio of the elemental components in the starting crystal. Compositional uniformity in the crystal is only obtained if there is no significant mixing in the liquid during growth. The technological importance of PbSnTe lies in its band gap versus composition diagram which has a zero energy crossing at approximately 40% SnTe. This facilitates the construction of long wavelength (greater than 6 gm) infrared detectors and lasers. The properties and utilization of PbSnTe are the subject of other papers. 1,2 PbSnTe is also interesting from a purely scientific point of view. It is, potentially, both solutally and thermally unstable due to the temperature and density gradients present during growth. Density gradients, through thermal expansion, are imposed in directional solidification because temperature gradients are required to extract heat. Solutal gradients occur in directional solidification of alloys due to segregation at the interface. Usually the gradients vary with both experiment design and inherent materials properties. In a simplified one dimensional analysis with the growth axis parallel to the gravity vector, only one of the two instabilities work at a time. During growth, the temperature in the liquid increases ahead of the interface. Therefore the density, due to thermal expansion, is decreasing in that direction. However, the phase diagram shows that the lighter SnTe is preferentially rejected at the interface. This causes the liquid density to increase with distance away from the interface.

Continuum simulation of heat transfer and solidification behavior of AlSi10Mg in Direct Metal Laser Sintering Process

NASA Astrophysics Data System (ADS)

Ojha, Akash; Samantaray, Mihir; Nath Thatoi, Dhirendra; Sahoo, Seshadev

2018-03-01

Direct Metal Laser Sintering (DMLS) process is a laser based additive manufacturing process, which built complex structures from powder materials. Using high intensity laser beam, the process melts and fuse the powder particles makes dense structures. In this process, the laser beam in terms of heat flux strikes the powder bed and instantaneously melts and joins the powder particles. The partial solidification and temperature distribution on the powder bed endows a high cooling rate and rapid solidification which affects the microstructure of the build part. During the interaction of the laser beam with the powder bed, multiple modes of heat transfer takes place in this process, that make the process very complex. In the present research, a comprehensive heat transfer and solidification model of AlSi10Mg in direct metal laser sintering process has been developed on ANSYS 17.1.0 platform. The model helps to understand the flow phenomena, temperature distribution and densification mechanism on the powder bed. The numerical model takes into account the flow, heat transfer and solidification phenomena. Simulations were carried out for sintering of AlSi10Mg powders in the powder bed having dimension 3 mm × 1 mm × 0.08 mm. The solidification phenomena are incorporated by using enthalpy-porosity approach. The simulation results give the fundamental understanding of the densification of powder particles in DMLS process.

Some Pecularities of Solidification of the Almandine Impact Melt

NASA Astrophysics Data System (ADS)

Feldman, V. I.; Kozlov, E. A.; Zhugin, Yu. N.

1996-03-01

SOME PECULIARITIES OF SOLIDIFICATION OF THE ALMANDINE IMPACT MELT. Feldman V.I. Moscow State University, Geological Faculty, Department of Petrology, 119899, Moscow, Russia. Kozlov E.A., Zhugin Yu.N. Russian Federal nuclear Center - Research Institute of Technical Physics, P.O.Box 245, 456770, Snezhinsk, Russia. The aim of these investigations is a description of the experiments and the first results of a loading of the garnet sand by spherical converging shock waves. These experiments show that impact liquid have by solidification three stage of liquid immiscibility.

Convective stability in the Rayleigh-Benard and directional solidification problems - High-frequency gravity modulation

NASA Technical Reports Server (NTRS)

Wheeler, A. A.; Mcfadden, G. B.; Murray, B. T.; Coriell, S. R.

1991-01-01

The effect of vertical, sinusoidal, time-dependent gravitational acceleration on the onset of solutal convection during directional solidification is analyzed in the limit of large modulation frequency. When the unmodulated state is unstable, the modulation amplitude required to stabilize the system is determined by the method of averaging. When the unmodulated state is stable, resonant modes of instability occur at large modulation amplitude. These are analyzed using matched asymptotic expansions to elucidate the boundary-layer structure for both the Rayleigh-Benard and directional solidification configurations. Based on these analyses, a thorough examination of the dependence of the stability criteria on the unmodulated Rayleigh number, Schmidt number, and distribution coefficient, is carried out.

Influence of additional heat exchanger block on directional solidification system for growing multi-crystalline silicon ingot - A simulation investigation

NASA Astrophysics Data System (ADS)

Nagarajan, S. G.; Srinivasan, M.; Aravinth, K.; Ramasamy, P.

2018-04-01

Transient simulation has been carried out for analyzing the heat transfer properties of Directional Solidification (DS) furnace. The simulation results revealed that the additional heat exchanger block under the bottom insulation on the DS furnace has enhanced the control of solidification of the silicon melt. Controlled Heat extraction rate during the solidification of silicon melt is requisite for growing good quality ingots which has been achieved by the additional heat exchanger block. As an additional heat exchanger block, the water circulating plate has been placed under the bottom insulation. The heat flux analysis of DS system and the temperature distribution studies of grown ingot confirm that the established additional heat exchanger block on the DS system gives additional benefit to the mc-Si ingot.

The growth of metastable peritectic compounds

NASA Technical Reports Server (NTRS)

Larson, D. J., Jr.; Pirich, R. G.

1981-01-01

The influence of gravitationally driven thermosolutal convection on the directional solidification of peritectic alloys is considered as well as the relationships between the solidification processing conditions, and the microstructure, chemistry, and magnetic properties of such alloys. Analysis of directionally solidified Pb-Bi peritectic samples indicates that appreciable macrosegregation occurs due to thermosolutal convection and/or Soret diffusion. A peritectic solidification model which accounts for partial mixing in the liquid ahead of the planar solidification interface and describes macrosegregation has been developed. Two-phase dendritic and banded microstructures were grown in the Pb-Bi peritectic system, refined two-phase microstructures have were observed, and candidate formation mechanisms proposed. Material handling, containment, casting, microstructural and magnetic characterization techniques were developed for the Sm-Co system. Alloys produced with these procedures are homogeneous.

Space Processing Application Rocket project, SPAR 5

NASA Technical Reports Server (NTRS)

Reeves, F. (Compiler); Schaefer, D. (Compiler)

1980-01-01

Post flight results and analysis are presented on the following experiments: 'Agglomeration in Immiscible Liquids', 'Contained Polycrystalline Solidification in Low G', 'The Direct Observation of Dendrite Remelting and Macrosegregation in Casting', and 'Uniform Dispersion by Crystallization'. An engineering report on the performance of the SPAR Black Brant rocket is also included. Much useful data and information were accumulated for directing and developing experimental techniques and investigations toward an expanding commercially beneficial program of materials processing in the coming shuttle era.

Transient and diffusion analysis of HgCdTe

NASA Technical Reports Server (NTRS)

Clayton, J. C.

1982-01-01

Solute redistribution during directional solidification of HgCdTe is addressed. Both one-dimensional and two-dimensional models for solute redistribution are treated and model results compared to experiment. The central problem studied is the cause of radial inhomogeneities found in directionally solidified HgCdTe. A large scale gravity-driven interface instability, termed shape instability, is postulated to be the cause of radial inhomogeneities. Recommendations for future work, along with appropriate computer programs, are included.

Macrosegregation and Grain Formation Caused by Convection Associated with Directional Solidification Through Cross-Section Increase

NASA Technical Reports Server (NTRS)

Ghods, Masoud; Lauer, Mark; Tewari, Surendra; Poirier, David; Grugel, Richard

2016-01-01

Cylindrical Al-7 wt% Silicon, Al-19 wt% Copper and Lead-6 wt% Antimony alloy samples were directionally solidified (DS) with liquid above, solid below, and gravity pointing down, in graphite crucibles having an abrupt cross-sectional increase. These alloys have similar solidification shrinkage but are expected to have different degrees of thermosolutal convection during solidification. Microstructures in the DS samples in the vicinity of the section change have been studied in order to examine the effect of convection associated with the combined influence of thermosolutal effects and solidification shrinkage. Extensive radial and axial macrosegregation associated with cross-section change is observed. It also appears that steepling and local primary alpha-phase remelting resulting from convection are responsible for stray grain formation at the reentrant corners. Preliminary results from a numerical model, which includes solidification shrinkage and thermosolutal convection in the mushy zone, indicate that these regions are prone to solutal remelting of dendrites.

Microstructure and Macrosegregation Study of Directionally Solidified Al-7Si Samples Processed Terrestrially and Aboard the International Space Station

NASA Technical Reports Server (NTRS)

Angart, Samuel; Erdman, R. G.; Poirier, David R.; Tewari, S.N.; Grugel, R. N.

2014-01-01

This talk reports research that has been carried out under the aegis of NASA as part of a collaboration between ESA and NASA for solidification experiments on the International Space Station (ISS). The focus has been on the effect of convection on the microstructural evolution and macrosegregation in hypoeutectic Al-Si alloys during directional solidification (DS). The DS-experiments have been carried out under 1-g at Cleveland State University (CSU) and under low-g on the International Space Station (ISS). The thermal processing-history of the experiments is well defined for both the terrestrially-processed samples and the ISS-processed samples. We have observed that the primary dendrite arm spacings of two samples grown in the low-g environment of the ISS show good agreement with a dendrite-growth model based on diffusion controlled growth. The gravity-driven convection (i.e., thermosolutal convection) in terrestrially grown samples has the effect of decreasing the primary dendrite arm spacings and causes macrosgregation. In order to process DS-samples aboard the ISS, dendritic-seed crystals have to partially remelted in a stationary thermal gradient before the DS is carried out. Microstructural changes and macrosegregation effects during this period are described.

Microstructure selection in thin-sample directional solidification of an Al-Cu alloy: In situ X-ray imaging and phase-field simulations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Clarke, A. J.; Tourret, D.; Song, Y.

We study microstructure selection during during directional solidification of a thin metallic sample. We combine in situ X-ray radiography of a dilute Al-Cu alloy solidification experiments with three-dimensional phase-field simulations. Here we explore a range of temperature gradient G and growth velocity V and build a microstructure selection map for this alloy. We investigate the selection of the primary dendritic spacing Λ and tip radius ρ. While ρ shows a good agreement between experimental measurements and dendrite growth theory, with ρ~V $-$1/2, Λ is observed to increase with V (∂Λ/∂V > 0), in apparent disagreement with classical scaling laws formore » primary dendritic spacing, which predict that ∂Λ/∂V<0. We show through simulations that this trend inversion for Λ(V) is due to liquid convection in our experiments, despite the thin sample configuration. We use a classical diffusion boundary-layer approximation to semi-quantitatively incorporate the effect of liquid convection into phase-field simulations. This approximation is implemented by assuming complete solute mixing outside a purely diffusive zone of constant thickness that surrounds the solid-liquid interface. This simple method enables us to quantitatively match experimental measurements of the planar morphological instability threshold and primary spacings over an order of magnitude in V. Lastly, we explain the observed inversion of ∂Λ/∂V by a combination of slow transient dynamics of microstructural homogenization and the influence of the sample thickness.« less

Microstructure selection in thin-sample directional solidification of an Al-Cu alloy: In situ X-ray imaging and phase-field simulations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Clarke, A. J.; Tourret, D.; Song, Y.

We study microstructure selection during directional solidification of a thin metallic sample. We combine in situ X-ray radiography of a dilute Al-Cu alloy solidification experiments with three-dimensional phase-field simulations. We explore a range of temperature gradient G and growth velocity V and build a microstructure selection map for this alloy. We investigate the selection of the primary dendritic spacing Lambda and tip radius rho. While rho shows a good agreement between experimental measurements and dendrite growth theory, with rho similar to V-1/2, Lambda is observed to increase with V (partial derivative Lambda/partial derivative V > 0), in apparent disagreement withmore » classical scaling laws for primary dendritic spacing, which predict that partial derivative Lambda/partial derivative V <0. We show through simulations that this trend inversion for Lambda(V) is due to liquid convection in our experiments, despite the thin sample configuration. We use a classical diffusion boundary-layer approximation to semi-quantitatively incorporate the effect of liquid convection into phase-field simulations. This approximation is implemented by assuming complete solute mixing outside a purely diffusive zone of constant thickness that surrounds the solid-liquid interface. This simple method enables us to quantitatively match experimental measurements of the planar morphological instability threshold and primary spacings over an order of magnitude in V. We explain the observed inversion of partial derivative Lambda/partial derivative V by a combination of slow transient dynamics of microstructural homogenization and the influence of the sample thickness.« less

Microstructure selection in thin-sample directional solidification of an Al-Cu alloy: In situ X-ray imaging and phase-field simulations

DOE PAGES

Clarke, A. J.; Tourret, D.; Song, Y.; ...

2017-05-01

We study microstructure selection during during directional solidification of a thin metallic sample. We combine in situ X-ray radiography of a dilute Al-Cu alloy solidification experiments with three-dimensional phase-field simulations. Here we explore a range of temperature gradient G and growth velocity V and build a microstructure selection map for this alloy. We investigate the selection of the primary dendritic spacing Λ and tip radius ρ. While ρ shows a good agreement between experimental measurements and dendrite growth theory, with ρ~V $-$1/2, Λ is observed to increase with V (∂Λ/∂V > 0), in apparent disagreement with classical scaling laws formore » primary dendritic spacing, which predict that ∂Λ/∂V<0. We show through simulations that this trend inversion for Λ(V) is due to liquid convection in our experiments, despite the thin sample configuration. We use a classical diffusion boundary-layer approximation to semi-quantitatively incorporate the effect of liquid convection into phase-field simulations. This approximation is implemented by assuming complete solute mixing outside a purely diffusive zone of constant thickness that surrounds the solid-liquid interface. This simple method enables us to quantitatively match experimental measurements of the planar morphological instability threshold and primary spacings over an order of magnitude in V. Lastly, we explain the observed inversion of ∂Λ/∂V by a combination of slow transient dynamics of microstructural homogenization and the influence of the sample thickness.« less

NBS (National Bureau of Standards): Materials measurements. [space processing experiments

NASA Technical Reports Server (NTRS)

Manning, J. R.

1983-01-01

Work directed toward the measurement of materials properties important to the design and interpretation of space processing experiments and determinations of how the space environment may offer a unique opportunity for performing improved measurements and producing materials with improved properties is reported. Surface tensions and their variations with temperature and impurities; convection during undirectional solidification; and measurement of the high temperature thermophysical properties of tungsten group liquids and solids are discussed and results are summarized.

Theoretical modeling of cellular and dendritic solidification microstructures

NASA Astrophysics Data System (ADS)

Song, Younggil

In this dissertation, we use three-dimensional (3D) phase-field (PF) modeling to investigate (i) 3D solid-liquid interface dynamics observed in microgravity experiments, and (ii) array patterns in a thin-sample geometry. In addition, using the two-dimensional (2D) dendritic-needle-network (DNN) model, we explore (iii) secondary sidebranching dynamics. Recently, solidification experiments are carried out in the DSI (Directional Solidification Insert) of the DECLIC (Device for the study of Critical LIquids and Crystallization) facility aboard the International Space Station (ISS). Thus, the directional solidification experiments are achieved under limited convective currents, and the experimental observations reveal unique dynamics of 3D microstructure in a purely diffusive growth regime. In this directional solidification setup, a temperature field between heat sources could evolve due to two main factors: (i) heat transfer within an adiabatic zone and (ii) latent heat rejection at the interface. These two thermal effects are phenomenologically characterized using a time-dependent thermal shift. In addition, we could quantitatively account for these thermal factors using a numerical calculation of the evolution of temperature field. We introduce these phenomenological and quantitative thermal representations into the PF model. The performed simulations using different thermal descriptions are compared to the experimental measurements from the initial planar interface dynamics to the final spacing selection. The DECLIC-DSI experimental observations exhibit complex grain boundary (GB) dynamics between large grains with a small misorientation. In the observations, several large grains with a small misorientation with respect to the temperature gradient are formed during solidification. Specifically, at a convergent GB, a localized group of misoriented cells penetrates into a nearby grain, which yields the morphological instability of grain boundaries. Remarkably, while the invasion process starts with a group of cells, the leader cell can detach itself from the group and grow continuously as a misoriented solitary cell in the other grain with a different misorientation. We use PF simulations to investigate the GB morphology and dynamics of a solitary cell. Solidification experiments on earth are typically performed in a thin-sample geometry to avoid fluid convection. Thus, we consider various influences on cellular and dendritic array patterns in thin samples. First, we explore the influence of crystal orientation. When a grain in a thin-sample geometry is misoriented with respect to the temperature gradient, primary cells and dendrites drift laterally in both experiments and simulations. At the same time, grain boundaries are systematically formed at the edges of the misoriented grain. The misoriented primary branches move away from the divergent grain boundary. At this boundary, cells/dendrites are generated continuously, and their spacings are larger than the dynamically selected spacings. Primary branches run into the other convergent GB, which leads to their elimination. Thus, at a stationary state, a spacing distribution is uniform with the spacing selected at the divergent GB until it decreases near the convergent GB. We perform simulations to illustrate the global evolutions of a primary spacing. In addition, we suggest a simple geometrical model and a nonlinear advection equation for the dynamics of the primary spacing evolution, which can predict the slow evolution of a primary spacing in a quasi-2D array. Experimental observations point out that the primary spacing selection could be affected by the sample thickness; however, the detailed description for the link between the primary spacing selection and a sample thickness is still missing. Here, we use PF simulations to investigate the primary cellular and dendritic spacing selection mechanisms under the influence of a sample thickness. A thin-sample geometry can limit thermal and solutal convective currents effectively. However, as the sample thickness increases, the convective currents can influence the solid- liquid interface dynamics. Then, the microstructure selection mechanisms can be different from the classical theories that are valid in a diffusive regime. We propose a simple approach for the PF model to demonstrate the microstructure selection when liquid convection is present. These simulations are compared to experimental results. Columnar microstructures with cells and dendrites typically form polycrystalline materials during directional solidification. Then, convergent and divergent grain boundaries form systematically between grains, which are misoriented with respect to the temperature gradient. Moreover, the GB is dynamically selected during the competition between two nearby misoriented grains. In order to investigate the GB orientation selection, we carry out 3D PF simulations in a thin-sample geometry. These simulations reveal the influence of the 3D GB bi-crystallography on grain competition. The results highlight the importance of considering the orientation of the orthogonal planes containing secondary branches in addition to the growth direction of primary branches. Finally, we propose three growth steps to demonstrate the secondary sidebranching growth dynamics under isothermal dendritic growth condition. (Abstract shortened by ProQuest.).

Directionally solidified article with weld repair

NASA Technical Reports Server (NTRS)

Smashey, Russell W. (Inventor); Snyder, John H. (Inventor); Borne, Bruce L. (Inventor)

2003-01-01

A directionally solidified nickel-base superalloy article has a defect therein extending parallel to the solidification direction. The article is repaired by removing any foreign matter present in the defect, and then heating the article to a repair temperature of from about 60 to about 98 percent of the solidus temperature of the base material in a chamber containing a protective gas that inhibits oxidation of the base material. The defect is filled with a filler metal while maintaining the article at the repair temperature. The filling is accomplished by providing a source of the filler metal of substantially the same composition as the base material of the directionally solidified article, and melting the filler metal into the defect progressively while moving the source of the filler metal relative to the article in a direction parallel to the solidification direction. Optionally, additional artificial heat extraction is accomplished in a heat-flow direction that is within about 45 degrees of the solidification direction, as the filler metal solidifies within the defect. The article may thereafter be heat treated.

Weld repair of directionally solidified articles

NASA Technical Reports Server (NTRS)

Smashey, Russell W. (Inventor); Snyder, John H. (Inventor); Borne, Bruce L. (Inventor)

2002-01-01

A directionally solidified nickel-base superalloy article has a defect therein extending parallel to the solidification direction. The article is repaired by removing any foreign matter present in the defect, and then heating the article to a repair temperature of from about 60 to about 98 percent of the solidus temperature of the base material in a chamber containing a protective gas that inhibits oxidation of the base material. The defect is filled with a filler metal while maintaining the article at the repair temperature. The filling is accomplished by providing a source of the filler metal of substantially the same composition as the base material of the directionally solidified article, and melting the filler metal into the defect progressively while moving the source of the filler metal relative to the article in a direction parallel to the solidification direction. Optionally, additional artificial heat extraction is accomplished in a heat-flow direction that is within about 45 degrees of the solidification direction, as the filler metal solidifies within the defect. The article may thereafter be heat treated.

Resistivity Distribution of Multicrystalline Silicon Ingot Grown by Directional Solidification

NASA Astrophysics Data System (ADS)

Sun, S. H.; Tan, Y.; Dong, W.; Zhang, H. X.; Zhang, J. S.

2012-06-01

The effects of impurities on the resistivity distribution and polarity of multicrystalline silicon ingot prepared by directional solidification were investigated in this article. The shape of the equivalence line of the resistivity in the vertical and cross sections was determined by the solid-liquid interface. Along the solidification height of silicon ingot, the conductive type changed from p-type in the lower part of the silicon ingot to n-type in the upper part of the silicon ingot. The resistivity in the vertical section of the silicon ingot initially increased along the height of the solidified part, and reached its maximum at the polarity transition position, then decreased rapidly along the height of solidified part and approached zero on the top of the ingot because of the accumulation of impurities. The variation of resistivity in the vertical section of the ingot has been proven to be deeply relevant to the distribution of Al, B, and P in the growth direction of solidification.

Segregation and convection in dendritic alloys

NASA Technical Reports Server (NTRS)

Poirier, D. R.

1990-01-01

Microsegregation in dentritic alloys is discussed, including solidification with and without thermal gradient, the convection of interdendritic liquid. The conservation of momentum, energy, and solute is considered. Directional solidification and thermosolutal convection are discussed.

Effect of boundary heat flux on columnar formation in binary alloys: A phase-field study

NASA Astrophysics Data System (ADS)

Du, Lifei; Zhang, Peng; Yang, Shaomei; Chen, Jie; Du, Huiling

2018-02-01

A non-isothermal phase-field model was employed to simulate the columnar formation during rapid solidification in binary Ni-Cu alloy. Heat flux at different boundaries was applied to investigate the temperature gradient effect on the morphology, concentration and temperature distributions during directional solidifications. With the heat flux input/extraction from boundaries, coupling with latent heat release and initial temperature gradient, temperature distributions are significantly changed, leading to solute diffusion changes during the phase-transition. Thus, irregular columnar structures are formed during the directional solidification, and the concentration distribution in solid columnar arms could also be changed due to the different growing speeds and temperature distributions at the solid-liquid interfaces. Therefore, applying specific heat conditions at the solidifying boundaries could be an efficient way to control the microstructure during solidifications.

Eutectic Formation During Solidification of Ni-Based Single-Crystal Superalloys with Additional Carbon

NASA Astrophysics Data System (ADS)

Wang, Fu; Ma, Dexin; Bührig-Polaczek, Andreas

2017-11-01

γ/ γ' eutectics' nucleation behavior during the solidification of a single-crystal superalloy with additional carbon was investigated by using directional solidification quenching method. The results show that the nucleation of the γ/ γ' eutectics can directly occur on the existing γ dendrites, directly in the remaining liquid, or on the primary MC-type carbides. The γ/γ' eutectics formed through the latter two mechanisms have different crystal orientations than that of the γ matrix. This suggests that the conventional Ni-based single-crystal superalloy castings with additional carbon only guarantee the monocrystallinity of the γ matrix and some γ/ γ' eutectics and, in addition to the carbides, there are other misoriented polycrystalline microstructures existing in macroscopically considered "single-crystal" superalloy castings.

Solidification under zero gravity: A Long Duration Exposure Facility (LDEF) experiment for an early space shuttle mission. [project planning

NASA Technical Reports Server (NTRS)

Bailey, J. A.

1976-01-01

Project planning for two series of simple experiments on the effect of zero gravity on the melting and freezing of metals and nonmetals is described. The experiments will be performed in the Long Duration Exposure Facility, and their purpose will be to study: (1) the general morphology of metals and nonmetals during solidification, (2) the location of ullage space (liquid-vapor interfaces), and (3) the magnitude of surface tension driven convection during solidification of metals and nonmetals. The preliminary design of the experiments is presented. Details of the investigative approach, experimental procedure, experimental hardware, data reduction and analysis, and anticipated results are given. In addition a work plan and cost analysis are provided.

Rapid Solidification in Bulk Ti-Nb Alloys by Single-Track Laser Melting

NASA Astrophysics Data System (ADS)

Roehling, John D.; Perron, Aurélien; Fattebert, Jean-Luc; Haxhimali, Tomorr; Guss, Gabe; Li, Tian T.; Bober, David; Stokes, Adam W.; Clarke, Amy J.; Turchi, Patrice E. A.; Matthews, Manyalibo J.; McKeown, Joseph T.

2018-05-01

Single-track laser melting experiments were performed on bulk Ti-Nb alloys to explore process parameters and the resultant macroscopic structure and microstructure. The microstructures in Ti-20Nb and Ti-50Nb (at.%) alloys exhibited cellular growth during rapid solidification, with average cell size of approximately 0.5 µm. Solidification velocities during cellular growth were calculated from images of melt tracks. Measurements of the composition in the cellular and intercellular regions revealed nonequilibrium partitioning and its dependence on velocity during rapid solidification. Experimental results were used to benchmark a phase-field model to describe rapid solidification under conditions relevant to additive manufacturing.

Gravitational Acceleration Effects on Macrosegregation: Experiment and Computational Modeling

NASA Technical Reports Server (NTRS)

Leon-Torres, J.; Curreri, P. A.; Stefanescu, D. M.; Sen, S.

1999-01-01

Experiments were performed under terrestrial gravity (1g) and during parabolic flights (10-2 g) to study the solidification and macrosegregation patterns of Al-Cu alloys. Alloys having 2% and 5% Cu were solidified against a chill at two different cooling rates. Microscopic and Electron Microprobe characterization was used to produce microstructural and macrosegregation maps. In all cases positive segregation occurred next to the chill because shrinkage flow, as expected. This positive segregation was higher in the low-g samples, apparently because of the higher heat transfer coefficient. A 2-D computational model was used to explain the experimental results. The continuum formulation was employed to describe the macroscopic transports of mass, energy, and momentum, associated with the solidification phenomena, for a two-phase system. The model considers that liquid flow is driven by thermal and solutal buoyancy, and by solidification shrinkage. The solidification event was divided into two stages. In the first one, the liquid containing freely moving equiaxed grains was described through the relative viscosity concept. In the second stage, when a fixed dendritic network was formed after dendritic coherency, the mushy zone was treated as a porous medium. The macrosegregation maps and the cooling curves obtained during experiments were used for validation of the solidification and segregation model. The model can explain the solidification and macrosegregation patterns and the differences between low- and high-gravity results.

The Relationship between Dendrite Arm Spacing and Cooling Rate of Al-Si Casting Alloys in High Pressure Die Casting

NASA Astrophysics Data System (ADS)

Cho, Jae-Ik; Kim, Cheol-Woo; Kim, Young-Chan; Choi, Se-Weon; Kang, Chang-Seog

The effects of cooling rate on the solidification behavior of Al-8.5%Si-3%Cu and Al-11%Si-3%Cu alloys were studied during high pressure die casting (HPDC). The HPDC experiment was conducted by using the dies with 3 steps for 3 different cooling rates. Because of the high in both melt temperature and pressure, it was difficult to obtain the temperature profile directly from HPDC specimen. Therefore, in this study, cylindrical bar castings with different diameter were poured to acquire the cooling curves at the solidification range of 15°C/s up to 100°C/s and then the microstructures were compared to estimate the cooling rate in HPDC. The solidification characteristics including liquidus/solidus temperature and dendrite arm spacing of each alloy and each cooling rate was analyzed and the results showed strong proportional relationship between dendrite arm spacing and cooling rate in HPDC. The results were also compared with the actual die casting specimens and MAGMA simulation.

Grain Refinement and Texture Mitigation in Low Boron Containing TiAl-Alloys

NASA Astrophysics Data System (ADS)

Hecht, Ulrike; Witusiewicz, Victor T.

2017-12-01

Controlling the grain size and texture of lamellar TiAl-alloys is essential for well-balanced creep and fatigue properties. Excellent refinement and texture mitigation are achieved in aluminum lean alloys by low boron additions of 0.2 at.%. This amount is sufficient to promote in situ formation of ultrafine borides during the last stages of body centered cubic (BCC) solidification. The borides subsequently serve as nucleation sites for hexagonal close packed (HCP) during the BCC-HCP phase transformation. Bridgman solidification experiments with alloy Ti-43Al-8Nb-0.2C-0.2B were performed under a different growth velocity, i.e., cooling rate, to evaluate the HCP grain size distribution and texture. For slow-to-moderate cooling rates, about 65% of HCP grains are randomly oriented, despite the pronounced texture of the parent BCC phase resulting from directional solidification. For high cooling rates, obtained by quenching, texture mitigation is less pronounced. Only 28% of the HCP grains are randomly oriented, the majority being crystallographic variants of the Burgers orientation relationship.

The use of a directional solidification technique to investigate the interrelationship of thermal parameters, microstructure and microhardness of Bi–Ag solder alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Spinelli, José Eduardo, E-mail: spinelli@ufscar.br; Silva, Bismarck Luiz; Cheung, Noé

2014-10-15

Bi–Ag alloys have been stressed as possible alternatives to replace Pb-based solder alloys. Although acceptable melting temperatures and suitable mechanical properties may characterize such alloys, as referenced in literature, there is a lack of comprehension regarding their microstructures (morphologies and sizes of the phases) considering a composition range from 1.5 to 4.0 wt.%Ag. In order to better comprehend such aspects and their correlations with solidification thermal parameters (growth rate, v and cooling rate, T-dot), directional solidification experiments were carried out under transient heat flow conditions. The effects of Ag content on both cooling rate and growth rate during solidification aremore » examined. Microstructure parameters such as eutectic/dendritic spacing, interphase spacing and diameter of the Ag-rich phase were determined by optical microscopy and scanning electron microscopy. The competition between eutectic cells and dendrites in the range from 1.5 to 4.0 wt.%Ag is explained by the coupled zone concept. Microhardness was determined for different microstructures and alloy Ag contents with a view to permitting correlations with microstructure parameters to be established. Hardness is shown to be directly affected by both solute macrosegregation and morphologies of the phases forming the Bi–Ag alloys, with higher hardness being associated with the cellular morphology of the Bi-2.5 and 4.0 wt.%Ag alloys. - Highlights: • Asymmetric zone of coupled growth for Bi–Ag is demonstrated. • Faceted Bi-rich dendrites have been characterized for Bi–1.5 wt.%Ag alloy. • Eutectic cells were shown for the Bi-2.5 and 4.0 wt.%Ag solder alloys. • Interphase spacing relations with G × v are able to represent the experimental scatters. • Hall-Petch type equations are proposed relating microstructural spacings to hardness.« less

Spurious Grain Formation at Cross-Sectional Expansion During Directional Solidification: Influence of Thermosolutal Convection

NASA Astrophysics Data System (ADS)

Ghods, M.; Lauer, M.; Upadhyay, S. R.; Grugel, R. N.; Tewari, S. N.; Poirier, D. R.

2018-04-01

Formation of spurious grains during directional solidification (DS) of Al-7 wt.% Si and Al-19 wt.% Cu alloys through an abrupt increase in cross-sectional area has been examined by experiments and by numerical simulations. Stray grains were observed in the Al-19 wt.% Cu samples and almost none in the Al-7 wt.% Si. The locations of the stray grains correlate well where numerical solutions indicate the solute-rich melt to be flowing up the thermal gradient faster than the isotherm velocity. It is proposed that the spurious grain formation occurred by fragmentation of slender tertiary dendrite arms was enhanced by thermosolutal convection. In Al-7 wt.% Si, the dendrite fragments sink in the surrounding melt and get trapped in the dendritic array growing around them, and therefore they do not grow further. In the Al-19 wt.% Cu alloy, on the other hand, the dendrite fragments float in the surrounding melt and some find conducive thermal conditions for further growth and become stray grains.

Research on the effect of coverage rate on the surface quality in laser direct writing process

NASA Astrophysics Data System (ADS)

Pan, Xuetao; Tu, Dawei

2017-07-01

Direct writing technique is usually used in femtosecond laser two-photon micromachining. The size of the scanning step is an important factor affecting the surface quality and machining efficiency of micro devices. According to the mechanism of two-photon polymerization, combining the distribution function of light intensity and the free radical concentration theory, we establish the mathematical model of coverage of solidification unit, then analyze the effect of coverage on the machining quality and efficiency. Using the principle of exposure equivalence, we also obtained the analytic expressions of the relationship among the surface quality characteristic parameters of microdevices and the scanning step, and carried out the numerical simulation and experiment. The results show that the scanning step has little influence on the surface quality of the line when it is much smaller than the size of the solidification unit. However, with increasing scanning step, the smoothness of line surface is reduced rapidly, and the surface quality becomes much worse.

Simulating the Effect of Space Vehicle Environments on Directional Solidification of a Binary Alloy

NASA Technical Reports Server (NTRS)

Westra, D. G.; Heinrich, J. C.; Poirier, D. R.

2003-01-01

Space microgravity missions are designed to provide a microgravity environment for scientific experiments, but these missions cannot provide a perfect environment, due to vibrations caused by crew activity, on-board experiments, support systems (pumps, fans, etc.), periodic orbital maneuvers, and water dumps. Therefore, it is necessary to predict the impact of these vibrations on space experiments, prior to performing them. Simulations were conducted to study the effect of the vibrations on the directional solidification of a dendritic alloy. Finite element ca!cu!attie?ls were dme with a simd2titcr based on a continuum model of dendritic solidification, using the Fractional Step Method (FSM). The FSM splits the solution of the momentum equation into two steps: the viscous intermediate step, which does not enforce continuity; and the inviscid projection step, which calculates the pressure and enforces continuity. The FSM provides significant computational benefits for predicting flows in a directionally solidified alloy, compared to other methods presently employed, because of the efficiency gains in the uncoupled solution of velocity and pressure. finite differences, arises when the interdendritic liquid reaches the eutectic temperature and concentration. When a node reaches eutectic temperature, it is assumed that the solidification of the eutectic liquid continues at constant temperature until all the eutectic is solidified. With this approach, solidification is not achieved continuously across an element; rather, the element is not considered solidified until the eutectic isotherm overtakes the top nodes. For microgravity simulations, where the convection is driven by shrinkage, it introduces large variations in the fluid velocity. When the eutectic isotherm reaches a node, all the eutectic must be solidified in a short period, causing an abrupt increase in velocity. To overcome this difficulty, we employed a scheme to numerically predict a more accurate value for the rate of change of fraction of liquid as the liquid in an element solidifies. The new method enables us to contrast results of simulations in which the alloy is subjected to no gravity or a steady-state acceleration versus simulations when the alloy is subjected to vibration disturbances; therefore, the effect of vibration disturbances can be assessed more accurately. To assess the impact of these vibration-perturbations, transient accelerometer data from a space shuttle mission are used as inputs for the simulation model. These on-orbit acceleration data were obtained from the Microgravity Science Division at Glenn Research Center (GRC- MSD) and are applied to the buoyancy term of the momentum equation in a simulation of a Pb-5.8 wt. % Sb alloy that solidifies in a thermal gradient of 4000 K/m and a translation velocity of 3 p d s . Figure 2 shows the vertical velocity of a node that begins in the all-liquid region and subsequently solidifies; the vibrations are applied at 5000 seconds in this simulation. An important difficulty, common to all solidification models based on finite elements or 2 The magnitudes of the velocity oscillations that are vibration-induced are very small and acceptable. The biggest concern is whether the concentration of the liquid near the dendrite tips is distorted because of the vibration-induced perturbations. Results for this case show no concentration oscillations present in the all-liquid region.

Modelling directional solidification

NASA Technical Reports Server (NTRS)

Wilcox, William R.

1990-01-01

The long range goal is to develop an improved understanding of phenomena of importance to directional solidification, to enable explanation and prediction of differences in behavior between solidification on Earth and in space. Emphasis during the period of this grant was on experimentally determining the influence of convection and freezing rate fluctuations on compositional homogeneity and crystalline perfection in the vertical Bridgman-Stockbarger technique. Heater temperature profiles, buoyancy-driven convection, and doping inhomogeneties were correlated using naphthalene doped with azulene. In addition the influence of spin-up/spin-down on compositional homogeneity and microstructure of indium gallium antimonide and the effect of imposed melting-freezing cycles on indium gallium antimonide are discussed.

Electromagnetic containerless undercooling facility and experiments for the Shuttle

NASA Technical Reports Server (NTRS)

Frost, R. T.; Flemings, M. C.; Szekely, J.; El-Kaddah, N.; Shiohara, Y.

1984-01-01

An electromagnetic furnace is being prepared for flights aboard the Space Shuttle. This apparatus is capable of melting metals and alloys up to 1400 C melting point by induction heating with subsequent solidification of the freely levitated melt without contact with any container. The solidification can be carried out with greatly reduced fields resulting in minimal heating and stirring of the free melt. Sequential specimens can be processed during flight. Several experiments are planned for a series of flights, beginning in 1985 with an undercooling experiment of NiSn alloys. These will be interspersed with detailed studies of fluid flow caused by low and high field levels in order to quantify the corresponding effect upon the solidification process.

Segregation effects during solidification in weightless melts

NASA Technical Reports Server (NTRS)

Li, C.; Gershinsky, M.

1974-01-01

The generalized problem of determining the temperature and solute concentration profiles during directional solidification of binary alloys with surface evaporation was mathematically formulated. Realistic initial and boundary conditions were defined, and a computer program was developed and checked out. The programs computes the positions of two moving boundaries, evaporation and solidification, and their velocities. Temperature and solute concentration profiles in the semiinfinite material body at selected instances of time are also computed.

Particle Engulfment and Pushing by Solidifying Interfaces. Pt. 2; Micro-Gravity Experiments and Theoretical Analysis

NASA Technical Reports Server (NTRS)

Stefanescu, Doru M.; Juretzko, Frank R.; Dhindaw, Brij K.; Catalina, Adrian; Sen, Subhayu; Curreri, Peter A.

1998-01-01

Results of the directional solidification experiments on Particle Engulfment and Pushing by Solidifying Interfaces (PEP) conducted on the space shuttle Columbia during the Life and Microgravity Science Mission are reported. Two pure aluminum (99.999%) 9 mm cylindrical rods, loaded with about 2 vol.% 500 micrometers diameter zirconia particles were melted and resolidified in the microgravity (microg) environment of the shuttle. One sample was processed at step-wise increased solidification velocity, while the other at step-wise decreased velocity. It was found that a pushing-to-engulfment transition (PET) occurred in the velocity range of 0.5 to 1 micrometers. This is smaller than the ground PET velocity of 1.9 to 2.4 micrometers. This demonstrates that natural convection increases the critical velocity. A previously proposed analytical model for PEP was further developed. A major effort to identify and produce data for the surface energy of various interfaces required for calculation was undertaken. The predicted critical velocity for PET was of 0.775 micrometers/s.

Solidification rate influence on orientation and mechanical properties of MAR-M-246+Hf

NASA Technical Reports Server (NTRS)

Hamilton, D.

1983-01-01

The influence of solidification rates on the orientation and mechanical properties of MAR-M-246+Hf was studied. The preferred orientation was found to be (001) for single crystals, with all samples with 45 degrees of (001). Tensile tests were performed at room temperature. The anisotropy of directionally solidified MAR-M-246+Hf was demonstrated by gage section deformation. Dendrite arm spacing and crystal growth were found to depend on solidification rates and source material conditions. The greatest strength occurred at lower solidification rates. Some single crystals were grown by control of growth rates without seeding.

Numerical Simulation of Polysilicon Solid-liquid Interface Transmogrification in Heat Transfer Process

NASA Astrophysics Data System (ADS)

Yang, Xi; Ma, Wenhui; Lv, Guoqiang; Zhang, Mingyu

2018-01-01

The shape of solid-liquid interface during the directional solidification process, which is difficult to be observed and measured in actual processes, controls the grain orientation and grain size of polysilicon ingot. We carried out numerical calculations of the directional solidification progress of polycrystalline silicon and invested the means to deal with the latent heat of solidification in numerical simulation. The distributions of the temperature field of the melt for the crystallization progress as well as the transformation of the solid-liquid interface were obtained. The simulation results are consistent with the experimental outcomes. The results show that the curvature of solid-liquid interface is small and stability, larger grain sized columnar crystal can be grown in the laboratory-scale furnace at a solidification rate of 10 μm•s-1. It shall provide important theoretical basis for metallurgical process and polysilicon production technology.

Minimizing Segregation During the Controlled Directional Solidification of Dendritic Alloys Publication: Metallurgical and Materials Transactions

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Fedoseyev, A. I.; Kim, S.; Curreri, Peter A. (Technical Monitor)

2002-01-01

Gravity-driven thermosolutal convection that arises during controlled directional solidification (DS) of dendritic alloys promotes detrimental macro-segregation (e.g. freckles and steepling) in products such as turbine blades. Considerable time and effort has been spent to experimentally and theoretically investigate this phenomena; although our knowledge has advanced to the point where convection can be modeled and accurately compared to experimental results, little has been done to minimize its onset and deleterious effects. The experimental work demonstrates that segregation can be. minimized and microstructural uniformity promoted when a slow axial rotation is applied to the sample crucible during controlled directional solidification processing. Numerical modeling utilizing continuation and bifurcation methods have been employed to develop accurate physical and mathematical models with the intent of identifying and optimizing processing parameters.

Experiments on Nucleation in Different Flow Regimes

NASA Technical Reports Server (NTRS)

Bayuzick, R. J.; Hofmeister, W. H.; Morton, C. M.; Robinson, M. B.

1999-01-01

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods. Dilatometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions.

Directional solidification of Bi-Mn alloys using an applied magnetic field

NASA Technical Reports Server (NTRS)

Decarlo, J. L.; Pirich, R. G.

1987-01-01

Off-eutectic compositions of Bi-Mn were directionally solidified in applied transverse magnetic fields up to 3 kG, to determine the effects on thermal and solutal convection. Plane front directional solidification of eutectic and near-eutectic Bi-Mn results in a two-phase rodlike morphology consisting of ferromagnetic MnBi rods in a Bi solid solution matrix. Compositions of either side of the eutectic were studied in growth orientations vertically up and down. Temperature gradient was monitored during growth by means of an in-situ thermocouple. For Bi-rich compositions, the magnetic field appeared to increase mixing as determined from thermal, morphological, chemical, and magnetic analyses. For Mn-rich compositions, morphological and chemical analyses suggest some reduction in mixing due to application of the magnetic force. The capability for carrying out directional solidification of Bi-Mn in high longitudinal magnetic fields was established.

Effect of solidification parameters on mechanical properties of directionally solidified Al-Rich Al-Cu alloys

NASA Astrophysics Data System (ADS)

Çadırlı, Emin

2013-05-01

Al(100-x)-Cux alloys (x=3 wt%, 6 wt%, 15 wt%, 24 wt% and 33 wt%) were prepared using metals of 99.99% high purity in vacuum atmosphere. These alloys were directionally solidified under steady-state conditions by using a Bridgman-type directional solidification furnace. Solidification parameters (G, V and ), microstructure parameters (λ1, λ2 and λE) and mechanical properties (HV, σ) of the Al-Cu alloys were measured. Microstructure parameters were expressed as functions of solidification parameters by using a linear regression analysis. The dependency of HV, σ on the cooling rate, microstructure parameters and composition were determined. According to experimental results, the microhardness and ultimate tensile strength of the solidified samples was increased by increasing the cooling rate and Cu content, but decreased with increasing microstructure parameters. The microscopic fracture surfaces of the different samples were observed using scanning electron microscopy. Fractographic analysis of the tensile fracture surfaces showed that the type of fracture significantly changed from ductile to brittle depending on the composition.

Investigation of the Relationship between Undercooling and Solidification Velocity

NASA Technical Reports Server (NTRS)

Bayuzick, Robert J.; Hofmeister, William H.

2004-01-01

This work was aimed at reconciling the differences between experimental measurements of the theoretical predictions of the solidification velocity as a function of undercooling. The theory proposed by Boettinger, Coriell and Trivedi (the BCT theory) has been one of the most widely used models for describing the nature of the solidification of undercooled metals and alloys. However, for undercoolings greater than about 5% of the absolute melting temperature, there is considerable discrepancy between theory and experiment. At these large undercoolings, experimental results exhibit a much lessened dependency of solidification velocity on undercooling than is predicted by theory. Furthermore, unpredicted plateaus in the solidification velocity as a function of undercooling are observed.

Modification of the Electromagnetic Levitator (EML) Hardware

NASA Technical Reports Server (NTRS)

Frost, R. T.

1985-01-01

The goals of this project are: (1) to study the upgrade requirements and approaches needed for incorporation of an Electromagnetic Levitator (EML) into the shuttle orbiter, (2) to work with members of the Electromagnetic Containerless Processing science working group (SWG) to define future experiments for the EML, and (3) to assist these investigators in further development of ground-based experiment techniques to the limits possible in the terrestrial gravitational environment. Present work is directed toward: (1) upgrading the EML flight apparatus to meet requirements of safety and integration interfaces with the MSL orbiter carrier, (2) development of new experiment components required to carry out approved experiments in undercooled solidification and associated fluid flow studies directed by MIT, and (3) construction, test, qualification and integration assistance for the EML MSL flight package.

Crystal Growth Using MEPHISTO

NASA Technical Reports Server (NTRS)

deGroh, Henry C., III

1999-01-01

The shuttle flight experiment "In Situ Monitoring of Crystal Growth Using MEPHISTO" was accomplished during STS-87 as part of the fourth flight of the United States Microgravity Payload (USMP-4), which was flown from November 19 to December 5, 1997. The data returned from that flight are just now beginning to yield quantitative results. This project is an international collaboration: the furnace system known as MEPHISTO was built in France by CNES (French National Space Agency) and CEA (French Atomic Energy Commission); the principal investigator, Prof. Reza Abbaschian, is from the University of Florida at Gainesville; and numerical and analytical modeling support includes collaborators from the University of New South Wales, Australia, the University of Wisconsin at Milwaukee, the National Institute of Standards and Technology, and the NASA Lewis Research Center. MEPHISTO is a French acronym that translates into English as Materials for the Study of Interesting Phenomena of Solidification on Earth and in Orbit. Since this was the fourth flight of the MEPHISTO furnace, the experiment is referred to as MEPHISTO-4. MEPHISTO-4 was a directional solidification experiment that studied the liquid-to-solid transformation of bismuth alloyed with tin. Directional solidification is a freezing technique common to the processing of the electronic materials used in integrated circuits and detectors, such as silicon and germanium. When liquids are frozen on Earth, they must be cooled. The cooling causes stirring because of density variations in the liquid. This stirring, known as natural convection, influences the quality of the resulting solid. During freezing, regions of high and low concentrations of tin are created. This introduces another important phenomenon: diffusion, or the movement by molecular action of matter from regions of high concentration to regions of lower concentration. In MEPHISTO-4, it is tin that diffuses from the high-concentration region in front of the solid-liquid interface to more distant low-concentration regions.

Pore Formation and Mobility Investigation (PPMI): Description and Initial Analysis of Experiments Conducted aboard the International Space Station

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Anilkumar, A. V.; Lee, C. P.

2003-01-01

Flow visualization experiments during the controlled directional melt back and re-solidification of succinonitrile (SCN) and SCN-water mixtures were conducted using the Pore Formation and Mobility Investigation (PFMI) apparatus in the glovebox facility (GBX) aboard the International Space Station. The study samples were initially 'cast' on earth under 450 millibar of nitrogen into 1 cm ID glass sample tubes approximately 30 cm in length, containing 6 in situ thermocouples. During the Space experiments, the processing parameters and flow visualization settings are remotely monitored and manipulated from the ground Telescience Center (TSC). The ground solidified sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. Bubbles of different sizes are seen to initiate at the melt interface and, upon release from the melting solid, translate at different speeds in the temperature field ahead of them before coming to rest. Over a period of time these bubbles dissolve into the melt. The gas-laden liquid is then directionally solidified in a controlled manner, generally starting at a rate of 1 micron /sec. Observation and preliminary analysis of bubble formation and mobility in pure SCN samples during melt back and the subsequent structure resulting during gas generation upon re-solidification are presented and discussed.

Pore Formation and Mobility Investigation (PFMI): Description and Initial Analysis of Experiments Conducted aboard the International Space Station

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Anilkumar, A. V.; Lee, C. P.

2002-01-01

Flow visualization experiments during the controlled directional melt back and re-solidification of succinonitrile (SCN) and SCN-water mixtures were conducted using the Pore Formation and Mobility Investigation (PFMI) apparatus in the glovebox facility (GBX) aboard the International Space Station. The study samples were initially "cast" on earth under 450 millibar of nitrogen into 1 cm ID glass sample tubes approximately 30 cm in length, containing 6 in situ thermocouples. During the Space experiments, the processing parameters and flow visualization settings are remotely monitored and manipulated from the ground Telescience Center (TSC). The ground solidified sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. Bubbles of different sizes are seen to initiate at the melt interface and, upon release from the melting solid, translate at different speeds in the temperature field ahead of them before coming to rest. Over a period of time these bubbles dissolve into the melt. The gas-laden liquid is then directionally solidified in a controlled manner, generally starting at a rate of 1 micron /sec. Observation and preliminary analysis of bubble formation and mobility in pure SCN samples during melt back and the subsequent structure resulting during gas generation upon re-solidification are presented and discussed.

Comparison of Directionally Solidified Samples Solidified Terrestrially and Aboard the International Space Station

NASA Technical Reports Server (NTRS)

Angart, S.; Lauer, M.; Tewari, S. N.; Grugel, R. N.; Poirier, D. R.

2014-01-01

This article reports research that has been carried out under the aegis of NASA as part of a collaboration between ESA and NASA for solidification experiments on the International Space Station (ISS). The focus has been on the effect of convection on the microstructural evolution and macrosegregation in hypoeutectic Al-Si alloys during directional solidification (DS). Terrestrial DS-experiments have been carried out at Cleveland State University (CSU) and under microgravity on the International Space Station (ISS). The thermal processing-history of the experiments is well defined for both the terrestrially processed samples and the ISS-processed samples. As of this writing, two dendritic metrics was measured: primary dendrite arm spacings and primary dendrite trunk diameters. We have observed that these dendrite-metrics of two samples grown in the microgravity environment show good agreements with models based on diffusion controlled growth and diffusion controlled ripening, respectively. The gravity-driven convection (i.e., thermosolutal convection) in terrestrially grown samples has the effect of decreasing the primary dendrite arm spacings and causes macrosegregation. Dendrite trunk diameters also show differences between the earth- and space-grown samples. In order to process DS-samples aboard the ISS, the dendritic seed crystals were partially remelted in a stationary thermal gradient before the DS was carried out. Microstructural changes and macrosegregation effects during this period are described and have modeled.

Tranpsort phenomena in solidification processing of functionally graded materials

NASA Astrophysics Data System (ADS)

Gao, Juwen

A combined numerical and experimental study of the transport phenomena during solidification processing of metal matrix composite functionally graded materials (FGMs) is conducted in this work. A multiphase transport model for the solidification of metal-matrix composite FGMs has been developed that accounts for macroscopic particle segregation due to liquid-particle flow and particle-solid interactions. An experimental study has also been conducted to gain physical insight as well as to validate the model. A novel method to in-situ measure the particle volume fraction using fiber optic probes is developed for transparent analogue solidification systems. The model is first applied to one-dimensional pure matrix FGM solidification under gravity or centrifugal field and is extensively validated against the experimental results. The mechanisms for the formation of particle concentration gradient are identified. Two-dimensional solidification of pure matrix FGM with convection is then studied using the model as well as experiments. The interaction among convection flow, solidification process and the particle transport is demonstrated. The results show the importance of convection in the particle concentration gradient formation. Then, simulations for alloy FGM solidification are carried out for unidirectional solidification as well as two-dimensional solidification with convection. The interplay among heat and species transport, convection and particle motion is investigated. Finally, future theoretical and experimental work is outlined.

An investigation of the elevated temperature cracking susceptibility of alloy C-22 weld-metal

NASA Astrophysics Data System (ADS)

Gallagher, Morgan Leo

Alloy C-22 is one of the most corrosion resistant Ni-Cr-Mo alloys available today, and is particularly versatile. As a result, Alloy C-22 is being considered for use in the construction of storage canisters for permanent disposal of radioactive waste in the Yucca Mountain Project. However, in such a critical application, weld related defects (such as these two forms of cracking) are simply unacceptable. Solidification cracking occurs when weld shrinkage strains are applied to liquid films that result from microsegregation during solidification. Many nickel-base alloys are susceptible to solidification cracking since they solidify as austenite and many of their alloying additions partition during solidification and form low melting eutectic constituents. The transvarestraint test was used to quantify the susceptibility of Alloy C-22 to solidification cracking. The solidification cracking temperature range (SCTR) was found to be approximately 50°C (90°F); this SCTR predicts that Alloy-C-22 will have only slightly higher susceptibility than known crack-resistant alloys, such as duplex stainless-steel 2205 and austenitic stainless-steel Type 304 (FN6). Ductility-dip cracking (DDC) is a solid-state cracking phenomenon that occurs below the effective solidus temperature in highly restrained austenitic alloys. Although this type of cracking is relatively uncommon, it can be costly in critical applications where there is a low tolerance for defects. This investigation used two separate tests to quantify the susceptibility of the alloy to DDC: the hot-ductility test and the strain-to-fracture (STF) test. The hot-ductility test revealed that Alloy C-22 weld-metal exhibits an intermediate temperature ductility-dip, with ductility recovery at the upper end of the testing temperature range. The ductility minimum in the hot-ductility tests occurred around 950°C (1742°F) in both the on-heating and on-cooling tests. The strain-to-fracture test also revealed Alloy C-22 to be susceptible to ductility-dip cracking. Alloy C-22 displayed a low threshold strain necessary to initiate cracking, a wide temperature range over which cracking occurred, and no recovery of ductility at the upper end of the testing temperature range. The recovery of ductility at the upper end of the testing temperature range in the hotductility test, and the absence of this recovery in the STF test, is explained by the recrystallization behavior of the metal. Alloy C-22 has a low stacking-fault-energy, as compared to other DDC susceptible nickel-base alloys, and accordingly requires higher levels of deformation before recrystallization begins. With the relatively low strains experienced by the samples in the STF test (less than ten-percent), cracking will occur before enough strain is accumulated to cause recrystallization. In the hot-ductility test, where the sample is pulled to failure, sufficient strain (forty-percent or greater) is applied such that recrystallization occurs. This recrystallization is responsible for the recovery of ductility at the high end of the testing temperature range in the hot-ductility test. The low threshold strain that is observed in the STF test is in part explained by the behavior of the metal during the thermal cycle of the test. Experimental observations indicate that tortuous (wavy) solidification grain boundaries (SGB) migrate, or straighten, during the temperature upslope and hold period of the STF test. This migration of the grain boundaries reduces the mechanical locking effect that tortuous grain boundaries provide, allowing cracking to occur at lower applied strains. Button-melting experiments were conducted to examine the effect of compositional variation on both solidification cracking and ductility-dip cracking susceptibility of the alloy. Molybdenum, tungsten, and iron were selected for variation, as previous research has shown these three elements to be significantly enriched or depleted in the terminal solidification products of Alloy C-22 weld-metal. The solidification temperature range and volume fraction of secondary phases were used as indicators of the susceptibility of the experimental alloys to solidification cracking and ductility-dip cracking, respectively. Previous research on nickel-base alloys has demonstrated that the solidification temperature range of an alloy is directly proportional to the susceptibility of the alloy to solidification cracking. Experiments conducted within this investigation indicate that increasing the volume fraction of secondary phases in Alloy C-22 acts to increase the elevated temperature cracking-resistance and ductility of the alloy. The solidification temperature ranges of the Alloy C-22 variants examined within the button-melting experiments did not significantly widen or narrow with increases in composition. These same compositional variations demonstrated that increasing amounts of molybdenum, tungsten, and iron increased the volume fraction of secondary phases, with each element having relatively the same potency. Based on the button melting experiments and thermodynamic simulations, it is expected that Alloy C-22 will have good resistance to weld solidification cracking over its entire composition range. (Abstract shortened by UMI.)

Multiscale X-ray and Proton Imaging of Bismuth-Tin Solidification

NASA Astrophysics Data System (ADS)

Gibbs, P. J.; Imhoff, S. D.; Morris, C. L.; Merrill, F. E.; Wilde, C. H.; Nedrow, P.; Mariam, F. G.; Fezzaa, K.; Lee, W.-K.; Clarke, A. J.

2014-08-01

The formation of structural patterns during metallic solidification is complex and multiscale in nature, ranging from the nanometer scale, where solid-liquid interface properties are important, to the macroscale, where casting mold filling and intended heat transfer are crucial. X-ray and proton imaging can directly interrogate structure, solute, and fluid flow development in metals from the microscale to the macroscale. X-rays permit high spatio-temporal resolution imaging of microscopic solidification dynamics in thin metal sections. Similarly, high-energy protons permit imaging of mesoscopic and macroscopic solidification dynamics in large sample volumes. In this article, we highlight multiscale x-ray and proton imaging of bismuth-tin alloy solidification to illustrate dynamic measurement of crystal growth rates and solute segregation profiles that can be that can be acquired using these techniques.

On the Coupling Mechanism of Equiaxed Crystal Generation with the Liquid Flow Driven by Natural Convection During Solidification

NASA Astrophysics Data System (ADS)

Stefan-Kharicha, Mihaela; Kharicha, Abdellah; Wu, Menghuai; Ludwig, Andreas

2018-02-01

The influence of the melt flow on the solidification structure is bilateral. The flow plays an important role in the solidification pattern, via the heat transfer, grain distribution, and segregations. On the other hand, the crystal structure, columnar or equiaxed, impacts the flow, via the thermosolutal convection, the drag force applied by the crystals on the melt flow, etc. As the aim of this research was to further explore the solidification-flow interaction, experiments were conducted in a cast cell (95 * 95 * 30 mm3), in which an ammonium chloride-water solution (between 27 and 31 wt pct NH4Cl) was observed as it solidified. The kinetic energy (KE) of the flow and the average flow velocity were calculated throughout the process. Measurements of the volume extension of the mush in the cell and the velocity of the solid front were also taken during the solidification experiment. During the mainly columnar experiments (8 cm liquid height) the flow KE continuously decreased over time. However, during the later series of experiments at higher liquid height (9.5 cm), the flow KE evolution presented a strong peak shortly after the start of solidification. This increase in the total flow KE correlated with the presence of falling equiaxed crystals. Generally, a clear correlation between the strength of the flow and the occurrence of equiaxed crystals was evident. The analysis of the results strongly suggests a fragmentation origin of equiaxed crystals appearing in the melt. The transition from purely columnar growth to a strongly equiaxed rain (CET) was found to be triggered by (a) the magnitude of the coupling between the flow intensity driven by the equiaxed crystals, and (b) the release and transport of the fragments by the same flow recirculating within the mushy zone.

Directional solidification of C8-BTBT films induced by temperature gradients and its application for transistors

NASA Astrophysics Data System (ADS)

Fujieda, Ichiro; Iizuka, Naoki; Onishi, Yosuke

2015-03-01

Because charge transport in a single crystal is anisotropic in nature, directional growth of single crystals would enhance device performance and reduce its variation among devices. For an organic thin film, a method based on a temperature gradient would offer advantages in throughput and cleanliness. In experiments, a temperature gradient was established in a spin-coated film of 2,7-dioctyl [1]benzothieno[3,2-b]benzothiophene (C8-BTBT) by two methods. First, a sample was placed on a metal plate bridging two heat stages. When one of the heat stages was cooled, the material started to solidify from the colder region. The melt-solid interface proceeded along the temperature gradient. Cracks were formed perpendicular to the solidification direction. Second, a line-shaped region on the film was continuously exposed to the light from a halogen lamp. After the heat stage was cooled, cracks similar to the first experiment were observed, indicating that the melt-solid interface moved laterally. We fabricated top-contact, bottom-gate transistors with these films. Despite the cracks, field-effect mobility of the transistors fabricated with these films was close to 6 cm2 /Vs and 4 cm2 /Vs in the first and second experiment, respectively. Elimination of cracks would improve charge transport and reduce performance variation among devices. It should be noted that the intense light from the halogen lamp did not damage the C8-BTBT films. The vast knowledge on laser annealing is now available for directional growth of this type of materials. The associated cost would be much smaller because an organic thin film melts at a low temperature.

Containerless solidification of oxide material using an electrostatic levitation furnace in microgravity

NASA Astrophysics Data System (ADS)

Yu, Jianding; Koshikawa, Naokiyo; Arai, Yasutomo; Yoda, Shinichi; Saitou, Hirofumi

2001-11-01

Containerless solidification of BiFeO 3 has been carried out in microgravity with an electrostatic levitation furnace (ELF) on board a sounding rocket (TR-IA). This was the first time the ELF was used in microgravity to study the solidification behavior of oxide insulator material. A spherical BiFeO 3 specimen with a diameter of 5 mm was laser heated and solidified in an oxygen and nitrogen mixture atmosphere. The microstructure resulting from solidification in the ELF was compared with that obtained from solidification in a 10 m drop tube and in crucibles. In the crucible experiments, the segregation of the primary Fe 2O 3 phase could not be suppressed, even if the cooling speed increased to 5000 K/s. However it did suppress in a 0.3 mm diameter droplet solidified in the drop tube experiment. This suggests that containerless processing effectively promoted the undercooling of the BiFeO 3 phase. In the microgravity experiment, although a homogeneous BiFeO 3 phase was not observed in the 5 mm spherical specimen, an anomalous fine cellular microstructure appeared due to high undercooling. In addition, the phase transitions of BiFeO 3 were measured by DTA from room temperature to 1523 K and its liquidus temperature was estimated to be 1423 K.

Crystal Growth Furnace - An overview of the system configuration and planned experiments on the First United States Microgravity Laboratory mission

NASA Technical Reports Server (NTRS)

Srinivas, R.; Schaefer, D. A.

1992-01-01

The Crystal Growth Furnace (CGF) system configuration for the First United States Microgravity Laboratory (USML-1) mission is reviewed, and the planned on-orbit experiments are briefly described. The CGF is configured to accommodate four scientific experiments involving crystal growth which are based on the classical Bridgman method and CVT method, including vapor transport crystal growth of mercury cadmium telluride; crystal growth of mercury zinc telluride by directional solidification; seeded Bridgman growth of zinc-doped cadmium telluride; and Bridgman growth of selenium-doped gallium arsenide.

Directional solidification at ultra-high thermal gradient

NASA Technical Reports Server (NTRS)

Flemings, M. C.; Lee, D. S.; Neff, M. A.

1980-01-01

A high gradient controlled solidification (HGC) furnace was designed and operated at gradients up to 1800 C/cm to continuously produce aluminum alloys. Rubber '0' rings for the water cooling chamber were eliminated, while still maintaining water cooling directly onto the solidified metal. An HGC unit for high temperature ferrous alloys was also designed. Successful runs were made with cast iron, at thermal gradients up to 500 C/cm.

Advanced Gradient Heating Facility (AGHF)

NASA Technical Reports Server (NTRS)

1998-01-01

This section of the publication includes papers entitled: (1) Coupled growth in hypermonotectics; (2) Directional solidification of refined Al-4 wt.% Cu alloys; (3) Effects of convection on interface curvature during growth of concentrated ternary compounds; (4) Directional solidification of Al-1.5 wt.% Ni alloys; (5) Interactive response of advancing phase boundaries to particles; (6) INTeractive Response of Advancing Phase boundaries to Particles-INTRAPP; and (7) Particle engulfment and pushing by solidifying interfaces.

A comparative study of quantitative microsegregation analyses performed during the solidification of the Ni-base superalloy CMSX-10

DOE Office of Scientific and Technical Information (OSTI.GOV)

Seo, Seong-Moon, E-mail: castme@kims.re.kr; Jeong, Hi-Won; Ahn, Young-Keun

Quantitative microsegregation analyses were systematically carried out during the solidification of the Ni-base superalloy CMSX-10 to clarify the methodological effect on the quantification of microsegregation and to fully understand the solidification microstructure. Three experimental techniques, namely, mushy zone quenching (MZQ), planar directional solidification followed by quenching (PDSQ), and random sampling (RS), were implemented for the analysis of microsegregation tendency and the magnitude of solute elements by electron probe microanalysis. The microprobe data and the calculation results of the diffusion field ahead of the solid/liquid (S/L) interface of PDSQ samples revealed that the liquid composition at the S/L interface is significantlymore » influenced by quenching. By applying the PDSQ technique, it was also found that the partition coefficients of all solute elements do not change appreciably during the solidification of primary γ. All three techniques could reasonably predict the segregation behavior of most solute elements. Nevertheless, the RS approach has a tendency to overestimate the magnitude of segregation for most solute elements when compared to the MZQ and PDSQ techniques. Moreover, the segregation direction of Cr and Mo predicted by the RS approach was found to be opposite from the results obtained by the MZQ and PDSQ techniques. This conflicting segregation behavior of Cr and Mo was discussed intensively. It was shown that the formation of Cr-rich areas near the γ/γ′ eutectic in various Ni-base superalloys, including the CMSX-10 alloy, could be successfully explained by the results of microprobe analysis performed on a sample quenched during the planar directional solidification of γ/γ′ eutectic. - Highlights: • Methodological effect on the quantification of microsegregation was clarified. • The liquid composition at the S/L interface was influenced by quenching. • The segregation direction of Cr varied depending on the experimental techniques. • Cr and Mo segregation in Ni-base superalloys was fully understood.« less

ISS-Experiments of Columnar-to-Equiaxed Transition in Solidification Processing

NASA Technical Reports Server (NTRS)

Sturz, Laszlo; Zimmermann, Gerhard; Gandin, Charles, Andre; Billia, Bernard; Magelinck, Nathalie; Nguyen-Thi, Henry; Browne, David John; Mirihanage, Wajira U.; Voss, Daniela; Beckermann, Christoph;

Oscillatory cellular patterns in three-dimensional directional solidification

NASA Astrophysics Data System (ADS)

Tourret, D.; Debierre, J.-M.; Song, Y.; Mota, F. L.; Bergeon, N.; Guérin, R.; Trivedi, R.; Billia, B.; Karma, A.

2015-10-01

We present a phase-field study of oscillatory breathing modes observed during the solidification of three-dimensional cellular arrays in microgravity. Directional solidification experiments conducted onboard the International Space Station have allowed us to observe spatially extended homogeneous arrays of cells and dendrites while minimizing the amount of gravity-induced convection in the liquid. In situ observations of transparent alloys have revealed the existence, over a narrow range of control parameters, of oscillations in cellular arrays with a period ranging from about 25 to 125 min. Cellular patterns are spatially disordered, and the oscillations of individual cells are spatiotemporally uncorrelated at long distance. However, in regions displaying short-range spatial ordering, groups of cells can synchronize into oscillatory breathing modes. Quantitative phase-field simulations show that the oscillatory behavior of cells in this regime is linked to a stability limit of the spacing in hexagonal cellular array structures. For relatively high cellular front undercooling (i.e., low growth velocity or high thermal gradient), a gap appears in the otherwise continuous range of stable array spacings. Close to this gap, a sustained oscillatory regime appears with a period that compares quantitatively well with experiment. For control parameters where this gap exists, oscillations typically occur for spacings at the edge of the gap. However, after a change of growth conditions, oscillations can also occur for nearby values of control parameters where this gap just closes and a continuous range of spacings exists. In addition, sustained oscillations at to the opening of this stable gap exhibit a slow periodic modulation of the phase-shift among cells with a slower period of several hours. While long-range coherence of breathing modes can be achieved in simulations for a perfect spatial arrangement of cells as initial condition, global disorder is observed in both three-dimensional experiments and simulations from realistic noisy initial conditions. In the latter case, erratic tip-splitting events promoted by large-amplitude oscillations contribute to maintaining the long-range array disorder, unlike in thin-sample experiments where long-range coherence of oscillations is experimentally observable.

Oscillatory cellular patterns in three-dimensional directional solidification

DOE PAGES

Tourret, D.; Debierre, J. -M.; Song, Y.; ...

2015-09-11

We present a phase-field study of oscillatory breathing modes observed during the solidification of three-dimensional cellular arrays in micro-gravity. Directional solidification experiments conducted onboard the International Space Station have allowed for the first time to observe spatially extended homogeneous arrays of cells and dendrites while minimizing the amount of gravity-induced convection in the liquid. In situ observations of transparent alloys have revealed the existence, over a narrow range of control parameters, of oscillations in cellular arrays with a period ranging from about 25 to 125 minutes. Cellular patterns are spatially disordered, and the oscillations of individual cells are spatiotemporally uncorrelatedmore » at long distance. However, in regions displaying short-range spatial ordering, groups of cells can synchronize into oscillatory breathing modes. Quantitative phase-field simulations show that the oscillatory behavior of cells in this regime is linked to a stability limit of the spacing in hexagonal cellular array structures. For relatively high cellular front undercooling (\\ie low growth velocity or high thermal gradient), a gap appears in the otherwise continuous range of stable array spacings. Close to this gap, a sustained oscillatory regime appears with a period that compares quantitatively well with experiment. For control parameters where this gap exist, oscillations typically occur for spacings at the edge of the gap. However, after a change of growth conditions, oscillations can also occur for nearby values of control parameters where this gap just closes and a continuous range of spacings exists. In addition, sustained oscillations at to the opening of this stable gap exhibit a slow periodic modulation of the phase-shift among cells with a slower period of several hours. While long-range coherence of breathing modes can be achieved in simulations for a perfect spatial arrangement of cells as initial condition, global disorder is observed in both three-dimensional experiments and simulations from realistic noisy initial conditions. The, erratic tip splitting events promoted by large amplitude oscillations contribute to maintaining the long-range array disorder, unlike in thin sample experiments where long-range coherence of oscillations is experimentally observable.« less

Oscillatory cellular patterns in three-dimensional directional solidification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tourret, D.; Debierre, J. -M.; Song, Y.

We present a phase-field study of oscillatory breathing modes observed during the solidification of three-dimensional cellular arrays in micro-gravity. Directional solidification experiments conducted onboard the International Space Station have allowed for the first time to observe spatially extended homogeneous arrays of cells and dendrites while minimizing the amount of gravity-induced convection in the liquid. In situ observations of transparent alloys have revealed the existence, over a narrow range of control parameters, of oscillations in cellular arrays with a period ranging from about 25 to 125 minutes. Cellular patterns are spatially disordered, and the oscillations of individual cells are spatiotemporally uncorrelatedmore » at long distance. However, in regions displaying short-range spatial ordering, groups of cells can synchronize into oscillatory breathing modes. Quantitative phase-field simulations show that the oscillatory behavior of cells in this regime is linked to a stability limit of the spacing in hexagonal cellular array structures. For relatively high cellular front undercooling (\\ie low growth velocity or high thermal gradient), a gap appears in the otherwise continuous range of stable array spacings. Close to this gap, a sustained oscillatory regime appears with a period that compares quantitatively well with experiment. For control parameters where this gap exist, oscillations typically occur for spacings at the edge of the gap. However, after a change of growth conditions, oscillations can also occur for nearby values of control parameters where this gap just closes and a continuous range of spacings exists. In addition, sustained oscillations at to the opening of this stable gap exhibit a slow periodic modulation of the phase-shift among cells with a slower period of several hours. While long-range coherence of breathing modes can be achieved in simulations for a perfect spatial arrangement of cells as initial condition, global disorder is observed in both three-dimensional experiments and simulations from realistic noisy initial conditions. The, erratic tip splitting events promoted by large amplitude oscillations contribute to maintaining the long-range array disorder, unlike in thin sample experiments where long-range coherence of oscillations is experimentally observable.« less

Microgravity

NASA Image and Video Library

1987-12-17

The MEPHISTO experiment is a cooperative American and French investigation of the fundamentals of crystal growth. MEPHISTO is a French-designed and built materials processing furnace. MEPHISTO experiments study solidation (also called freezing) during the growth cycle of liquid materials used for semiconductor crystals. Solidification is the process where materials change from liquid (melt) to solid. An example of the solidification process is water changing into ice.

Successful Isothermal Dendritic Growth Experiment (IDGE) Proves Current Theories of Dendritic Solidification are Flawed

NASA Technical Reports Server (NTRS)

1996-01-01

The scientific objective of the Isothermal Dendritic Growth Experiment (IDGE) is to test fundamental assumptions about dendritic solidification of molten materials. "Dendrites"-- from the ancient Greek word for tree--are tiny branching structures that form inside molten metal alloys when they solidify during manufacturing. The size, shape, and orientation of the dendrites have a major effect on the strength, ductility (ability to be molded or shaped), and usefulness of an alloy. Nearly all of the cast metal alloys used in everyday products (such as automobiles and airplanes) are composed of thousands to millions of tiny dendrites. Gravity, present on Earth, causes convection currents in molten alloys that disturb dendritic solidification and make its precise study impossible. In space, gravity is negated by the orbiting of the space shuttle. Consequently, IDGE (which was conducted on the space shuttle) gathered the first precise data regarding undisturbed dendritic solidification. IDGE is a microgravity materials science experiment that uses an apparatus which was designed, built, tested, and operated by people from the NASA Lewis Research Center. This experiment was conceived by the principal investigator, Professor Martin E. Glicksman, from Rensselaer Polytechnic Institute in Troy, New York. The experiment was a team effort of Lewis civil servants, contractors from Aerospace Design & Fabrication Inc. (ADF), and personnel at Rensselaer.

Effects of a High Magnetic Field on the Microstructure of Ni-Based Single-Crystal Superalloys During Directional Solidification

NASA Astrophysics Data System (ADS)

Xuan, Weidong; Lan, Jian; Liu, Huan; Li, Chuanjun; Wang, Jiang; Ren, Weili; Zhong, Yunbo; Li, Xi; Ren, Zhongming

2017-08-01

High magnetic fields are widely used to improve the microstructure and properties of materials during the solidification process. During the preparation of single-crystal turbine blades, the microstructure of the superalloy is the main factor that determines its mechanical properties. In this work, the effects of a high magnetic field on the microstructure of Ni-based single-crystal superalloys PWA1483 and CMSX-4 during directional solidification were investigated experimentally. The results showed that the magnetic field modified the primary dendrite arm spacing, γ' phase size, and microsegregation of the superalloys. In addition, the size and volume fractions of γ/ γ' eutectic and the microporosity were decreased in a high magnetic field. Analysis of variance (ANOVA) results showed that the effect of a high magnetic field on the microstructure during directional solidification was significant ( p < 0.05). Based on both experimental results and theoretical analysis, the modification of microstructure was attributed to thermoelectric magnetic convection occurring in the interdendritic regions under a high magnetic field. The present work provides a new method to optimize the microstructure of Ni-based single-crystal superalloy blades by applying a high magnetic field.

Effect of Multi-Scale Thermoelectric Magnetic Convection on Solidification Microstructure in Directionally Solidified Al-Si Alloys Under a Transverse Magnetic Field

NASA Astrophysics Data System (ADS)

Li, Xi; Du, Dafan; Gagnoud, Annie; Ren, Zhongming; Fautrelle, Yves; Moreau, Rene

2014-11-01

The influence of a transverse magnetic field ( B < 1 T) on the solidification structure in directionally solidified Al-Si alloys was investigated. Experimental results indicate that the magnetic field caused macrosegregation, dendrite refinement, and a decrease in the length of the mushy zone in both Al-7 wt pct Si alloy and Al-7 wt pct Si-1 wt pct Fe alloys. Moreover, the application of the magnetic field is capable of separating the Fe-rich intermetallic phases from Al-7 wt pct Si-1 wt pct Fe alloy. Thermoelectric magnetic convection (TEMC) was numerically simulated during the directional solidification of Al-Si alloys. The results reveal that the TEMC increases to a maximum () when the magnetic field reaches a critical magnetic field strength (), and then decreases as the magnetic field strength increases further. The TEMC exhibits the multi-scales effects: the and values are different at various scales, with decreasing and increasing as the scale decreases. The modification of the solidification structure under the magnetic field should be attributed to the TEMC on the sample and dendrite scales.

Macrosegregation in Al-7Si alloy caused by abrupt cross-section change during directional solidification

NASA Astrophysics Data System (ADS)

Ghods, M.; Johnson, L.; Lauer, M.; Grugel, R. N.; Tewari, S. N.; Poirier, D. R.

2016-09-01

Hypoeutectic Al-7 wt .% Si alloys were directionally solidified vertically downward in cylindrical molds that incorporated an abrupt cross-section decrease (9.5 mm to 3.2 mm diameter) which, after 5 cm, reverted back to 9.5 mm diameter in a Bridgman furnace; two constant growth speeds and thermal gradients were investigated. Thermosolutal convection and cross-section-change-induced shrinkage flow effects on macrosegregation were investigated. Dendrite clustering and extensive radial macrosegregation was seen, particularly in the larger cross-sections, before contraction and after expansion, this more evident at the lower growth speed. This alloy shows positive longitudinal macrosegregation near cross-section decrease followed by negative macrosegregation right after it; the extent of macrosegregation, however, decreases with increasing growth speed. Primary dendrite steepling intensified as solidification proceeded into the narrower section and negative longitudinal macrosegregation was seen on the re-entrant shelves at expansion. A two-dimensional model accounting for both shrinkage and thermo-solutal convection was used to simulate solidification and the resulting mushy-zone steepling and macrosegregation. The experimentally observed longitudinal and radial macrosegregation associated with the cross-section changes during directional solidification of an Al-7Si alloy is well captured by the numerical simulations.

IJEMS: Iowa Joint Experiment in Microgravity Solidification

NASA Technical Reports Server (NTRS)

Bendle, John R.; Mashl, Steven J.; Hardin, Richard A.

1995-01-01

The Iowa Joint Experiment in Microgravity Solidification (IJEMS) is a cooperative effort between Iowa State University and the University of Iowa to study the formation of metal-matrix composites in a microgravity environment. Of particular interest is the interaction between the solid/liquid interface and the particles in suspension. The experiment is scheduled to fly on STS-69, Space Shuttle Endeavor on August 3, 1995. This project is unique in its heavy student participation and cooperation between the universities involved.

Indirect measurement of the solid/liquid interface using the minimization technique

DOE Office of Scientific and Technical Information (OSTI.GOV)

Choi, H.; Chun, M.

1985-11-01

The phenomenon of solidification of a flowing fluid in a vertical tube is closely related to the relocation dynamics of molten nuclear fuels in hypothetical core-disruptive accidents of a liquid-metal fast breeder reactor. The knowledge of the transient shape and the position of the liquid/solid interface is of practical importance in analysis of phase change processes. Sparrow and Broadbent directly measured the solid liquid interface via experiments, whereas Viskanta observed the solid/liquid interface motion via a photographic method. In this paper, a new method to predict the transient position of the solid/liquid interface is developed. This method is based onmore » the minimization technique. To use this method one needs the temperature of the wall on which the phase change is to take place. The new technique is useful, in particular, for the case of inward solidification of a flowing fluid in a tube where direct measurement of the solid/liquid interface is not possible, whereas the tube wall temperature measurement is relatively easy.« less

Three dimensional modelling of grain boundary interaction and evolution during directional solidification of multi-crystalline silicon

NASA Astrophysics Data System (ADS)

Jain, T.; Lin, H. K.; Lan, C. W.

2018-03-01

The development of grain structures during directional solidification of multi-crystalline silicon (mc-Si) plays a crucial role in the materials quality for silicon solar cells. Three dimensional (3D) modelling of the grain boundary (GB) interaction and evolution based on phase fields by considering anisotropic GB energy and mobility for mc-Si is carried out for the first time to elucidate the process. The energy and mobility of GBs are allowed to depend on misorientation and the GB plane. To examine the correctness of our method, the known the coincident site lattice (CSL) combinations such as (∑ a + ∑ b → ∑ a × b) or (∑ a + ∑ b → ∑ a / b) are verified. We frther discuss how to use the GB normal to characterize a ∑ 3 twin GB into a tilt or a twist one, and show the interaction between tilt and twist ∑ 3 twin GBs. Two experimental scenarios are considered for comparison and the results are in good agreement with the experiments as well as the theoretical predictions.

Mechanical interactions between ice crystals and red blood cells during directional solidification.

PubMed

Ishiguro, H; Rubinsky, B

1994-10-01

Experiments in which red blood cells were frozen on a directional solidification stage under a microscope show that there is a mechanical interaction between ice crystals and cells in which cells are pushed and deformed by the ice crystals. The mechanical interaction occurs during freezing of cells in physiological saline and is significantly inhibited by the addition of 20% v/v glycerol to the solution. The addition of osmotically insignificant quantities of antifreeze proteins from the winter flounder or ocean pout to the physiological saline with 20% v/v glycerol generates strong mechanical interactions between the ice and the cells. The cells were destroyed during freezing in physiological saline, survived freezing in physiological saline with glycerol, and were completely destroyed by the addition of antifreeze proteins to the solution with glycerol. The difference in cell survival through freezing and thawing appears to be related, in part, to the habit of ice crystal growing in the suspension of red blood cells and the nature of mechanical interaction between the ice crystal and the cells. This suggests that mechanical damage may be a factor during cryopreservation of cells.

Dendritic growth and structure of undercooled nickel base alloys

NASA Technical Reports Server (NTRS)

Flemings, M. C.; Shiohara, Y.

1988-01-01

The principal objectives of this overall investigation are to: study means for obtaining high undercooling in levitation melted droplets, and study structures produced upon the solidification of these undercooled specimens. Thermal measurements are made of the undercooling, and of the rapid recalescence, to develop an understanding of the solidification mechanism. Comparison of results is made with the modeling studies. Characterization and metallographic work is done to gain an understanding of the relationship between rapid solidification variables and the structures so produced. In ground based work to date, solidification of undercooled Ni-25 wt percent Sn alloy was observed by high-speed cinematography and the results compared with optical temperature measurements. Also in ground based work, high-speed optical temperature measurements were made of the solidification behavior of levitated metal samples within a transparent glass medium. Two undercooled Ni-Sn alloys were examined. Measurements were carried out on samples at undercoolings up to 330 K. Microstructures of samples produced in ground based work were determined by optical metallography and by SEM, and microsegregation by electron microprobe measurements. A series of flight tests were planned to conduct experiments similar to the ground based experiments. The Space Shuttle Columbia carried an alloy undercooled experiment in the STS 61-C mission in January 1986. A sample of Ni-32.5 wt percent Sn eutectic was melted and solidified under microgravity conditions.

Performance testing of a vertical Bridgman furnace using experiments and numerical modeling

NASA Astrophysics Data System (ADS)

Rosch, W. R.; Fripp, A. L.; Debnam, W. J.; Pendergrass, T. K.

1997-04-01

This paper details a portion of the work performed in preparation for the growth of lead tin telluride crystals during a Space Shuttle flight. A coordinated effort of experimental measurements and numerical modeling was completed to determine the optimum growth parameters and the performance of the furnace. This work was done using NASA's Advanced Automated Directional Solidification Furnace, but the procedures used should be equally valid for other vertical Bridgman furnaces.

OVERVIEW OF THE HISTORY, PRESENT STATUS, AND FUTURE DIRECTION OF SOLIDIFICATION/STABILIZATION TECHNOLOGIES FOR HAZARDOUS WASTE TREATMENT

EPA Science Inventory

Solidification/stabilization (S/S) technology processes are currently being utilized in the United States to treat inorganic and organic hazardous waste and radioactive waste. These wastes are generated from operating industry or have resulted from the uncontrolled management of ...

Influence of convection on microstructure

NASA Technical Reports Server (NTRS)

Wilcox, William R.; Caram, Rubens; Mohanty, A. P.; Seth, Jayshree

1990-01-01

The mechanism responsible for the difference in microstructure caused by solidifying the MnBi-Bi eutectic in space is sought. The objectives for the three year period are as follows: (1) completion of the following theoretical analyses - determination of the influence of the Soret effect on the average solid composition versus distance of off-eutectic mixtures directionally solidified in the absence of convection, determination of the influence of convection on the microstructure of off-eutectic mixtures using a linear velocity profile in the adjacent melt, determination of the influence of volumetric changes during solidification on microconvection near the freezing interface and on microstructure, and determination of the influence of convection on microstructure when the MnBi fibers project out in front of the bismuth matrix; (2) search for patterns in the effect of microgravity on different eutectics (for example, eutectic composition, eutectic temperature, usual microstructure, densities of pure constituents, and density changes upon solidification); and (3) determination of the Soret coefficient and the diffusion coefficient for Mn-Bi melts near the eutectic composition, both through laboratory experiements to be performed here and from data from Shuttle experiments.

Removal of inclusions from silicon

NASA Astrophysics Data System (ADS)

Ciftja, Arjan; Engh, Thorvald Abel; Tangstad, Merete; Kvithyld, Anne; Øvrelid, Eivind Johannes

2009-11-01

The removal of inclusions from molten silicon is necessary to satisfy the purity requirements for solar grade silicon. This paper summarizes two methods that are investigated: (i) settling of the inclusions followed by subsequent directional solidification and (infiltration by ceramic foam filters. Settling of inclusions followed by directional solidification is of industrial importance for production of low-cost solar grade silicon. Filtration is reported as the most efficient method for removal of inclusions from the top-cut silicon scrap.

A quasi two-dimensional benchmark experiment for the solidification of a tin lead binary alloy

NASA Astrophysics Data System (ADS)

Wang, Xiao Dong; Petitpas, Patrick; Garnier, Christian; Paulin, Jean-Pierre; Fautrelle, Yves

2007-05-01

A horizontal solidification benchmark experiment with pure tin and a binary alloy of Sn-10 wt.%Pb is proposed. The experiment consists in solidifying a rectangular sample using two lateral heat exchangers which allow the application a controlled horizontal temperature difference. An array of fifty thermocouples placed on the lateral wall permits the determination of the instantaneous temperature distribution. The cases with the temperature gradient G=0, and the cooling rates equal to 0.02 and 0.04 K/s are studied. The time evolution of the interfacial total heat flux and the temperature field are recorded and analyzed. This allows us to evaluate heat transfer evolution due to natural convection, as well as its influence on the solidification macrostructure. To cite this article: X.D. Wang et al., C. R. Mecanique 335 (2007).

STS-26 crewmembers experiment with microgravity and eat on middeck

NASA Technical Reports Server (NTRS)

1988-01-01

STS-26 Mission Specialist John M. Lounge, using a beverage container, experiments with microgravity as Commander Frederick H. Hauck (left) and MS David C. Hilmers (right) look on. Lounge freefloats as he closes in on a sphere of the red liquid drifting in front of his mouth. Hauck holds a spoon while sipping from a beverage container as he balances a meal tray assembly on his thighs. Hilmers, partially blocked by the open airlock hatch and holding a spoon and a can of food, pauses to watch the experiment. Automated Directional Solidification Furnace (ADSF) and forward middeck lockers appear on Lounge's right.

Evolution of Secondary Phases Formed upon Solidification of a Ni-Based Alloy

NASA Astrophysics Data System (ADS)

Zuo, Qiang; Liu, Feng; Wang, Lei; Chen, Changfeng

2013-07-01

The solidification of UNS N08028 alloy subjected to different cooling rates was studied, where primary austenite dendrites occur predominantly and different amounts of sigma phase form in the interdendritic regions. The solidification path and elemental segregation upon solidification were simulated using the CALPHAD method, where THERMO-CALC software packages and two classical segregation models were employed to predict the real process. It is thus revealed that the interdendritic sigma phase is formed via eutectic reaction at the last stage of solidification. On this basis, an analytical model was developed to predict the evolution of nonequilibrium eutectic phase, while the isolated morphology of sigma phase can be described using divorced eutectic theory. Size, fraction, and morphology of the sigma phase were quantitatively studied by a series of experiments; the results are in good agreement with the model prediction.

From Solidification Processing to Microstructure to Mechanical Properties: A Multi-scale X-ray Study of an Al-Cu Alloy Sample

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tourret, D.; Mertens, J. C. E.; Lieberman, E.

We follow an Al-12 at. pct Cu alloy sample from the liquid state to mechanical failure, using in situ X-ray radiography during directional solidification and tensile testing, as well as three-dimensional computed tomography of the microstructure before and after mechanical testing. The solidification processing stage is simulated with a multi-scale dendritic needle network model, and the micromechanical behavior of the solidified microstructure is simulated using voxelized tomography data and an elasto-viscoplastic fast Fourier transform model. This study demonstrates the feasibility of direct in situ monitoring of a metal alloy microstructure from the liquid processing stage up to its mechanical failure,more » supported by quantitative simulations of microstructure formation and its mechanical behavior.« less

Cellular interface morphologies in directional solidification. III - The effects of heat transfer and solid diffusivity

NASA Technical Reports Server (NTRS)

Ungar, Lyle H.; Bennett, Mark J.; Brown, Robert A.

1985-01-01

The shape and stability of two-dimensional finite-amplitude cellular interfaces arising during directional solidification are compared for several solidification models that account differently for latent heat released at the interface, unequal thermal conductivities of melt and solid, and solute diffusivity in the solid. Finite-element analysis and computer-implemented perturbation methods are used to analyze the families of steadily growing cellular forms that evolve from the planar state. In all models a secondary bifurcation between different families of finite-amplitude cells exists that halves the spatial wavelength of the stable interface. The quantitative location of this transition is very dependent on the details of the model. Large amounts of solute diffusion in the solid retard the growth of large-amplitude cells.

From Solidification Processing to Microstructure to Mechanical Properties: A Multi-scale X-ray Study of an Al-Cu Alloy Sample

DOE PAGES

Tourret, D.; Mertens, J. C. E.; Lieberman, E.; ...

2017-09-13

We follow an Al-12 at. pct Cu alloy sample from the liquid state to mechanical failure, using in situ X-ray radiography during directional solidification and tensile testing, as well as three-dimensional computed tomography of the microstructure before and after mechanical testing. The solidification processing stage is simulated with a multi-scale dendritic needle network model, and the micromechanical behavior of the solidified microstructure is simulated using voxelized tomography data and an elasto-viscoplastic fast Fourier transform model. This study demonstrates the feasibility of direct in situ monitoring of a metal alloy microstructure from the liquid processing stage up to its mechanical failure,more » supported by quantitative simulations of microstructure formation and its mechanical behavior.« less

From Solidification Processing to Microstructure to Mechanical Properties: A Multi-scale X-ray Study of an Al-Cu Alloy Sample

NASA Astrophysics Data System (ADS)

Tourret, D.; Mertens, J. C. E.; Lieberman, E.; Imhoff, S. D.; Gibbs, J. W.; Henderson, K.; Fezzaa, K.; Deriy, A. L.; Sun, T.; Lebensohn, R. A.; Patterson, B. M.; Clarke, A. J.

2017-11-01

We follow an Al-12 at. pct Cu alloy sample from the liquid state to mechanical failure, using in situ X-ray radiography during directional solidification and tensile testing, as well as three-dimensional computed tomography of the microstructure before and after mechanical testing. The solidification processing stage is simulated with a multi-scale dendritic needle network model, and the micromechanical behavior of the solidified microstructure is simulated using voxelized tomography data and an elasto-viscoplastic fast Fourier transform model. This study demonstrates the feasibility of direct in situ monitoring of a metal alloy microstructure from the liquid processing stage up to its mechanical failure, supported by quantitative simulations of microstructure formation and its mechanical behavior.

Metastable and unstable cellular solidification of colloidal suspensions

NASA Astrophysics Data System (ADS)

Deville, Sylvain; Maire, Eric; Bernard-Granger, Guillaume; Lasalle, Audrey; Bogner, Agnès; Gauthier, Catherine; Leloup, Jérôme; Guizard, Christian

2009-12-01

Colloidal particles are often seen as big atoms that can be directly observed in real space. They are therefore becoming increasingly important as model systems to study processes of interest in condensed-matter physics such as melting, freezing and glass transitions. The solidification of colloidal suspensions has long been a puzzling phenomenon with many unexplained features. Here, we demonstrate and rationalize the existence of instability and metastability domains in cellular solidification of colloidal suspensions, by direct in situ high-resolution X-ray radiography and tomography observations. We explain such interface instabilities by a partial Brownian diffusion of the particles leading to constitutional supercooling situations. Processing under unstable conditions leads to localized and global kinetic instabilities of the solid/liquid interface, affecting the crystal morphology and particle redistribution behaviour.

Solidification Using a Baffle in Sealed Ampoules (SUBSA)

NASA Technical Reports Server (NTRS)

Marin, C.; Ostrogorsky, A. G.; Volz, M.; Luz, P.; Jeter, L.; Spivey, R.; Burton, H.; Smith, G.; Knowles, T. R.; Bonner, W. A.

2003-01-01

Solidification Using a Baffle in Sealed Ampoules (SUBSA) will be the first materials science experiment conducted in the Microgravity Science Glovebox (MSG) Facility at the International Space Station (ISS) Alpha. The launch is schedule for May 31, 2002. Using the specially developed furnace, 10 Te and Zn-doped single crystals of InSb will be directionally solidified in microgravity. A key goal of the SUBSA investigation is to (i) clarify the origin of the melt motion in space laboratories and (ii) to reduce the magnitude of the melt motion to the point that it does not interfere with the transport phenomena. These goals will be accomplished through a special ampoule and furnace design. A disk-shaped baffle, positioned close to the freezing front, is used to reduce melt motion. Furthermore, the solidification will be visualized by using a transparent furnace, with a video camera, continuously sending images to the earth. This allows detection of bubbles and melt de-wetting that could cause surface tension driven convection. In preparation for the space experiments, 30 ground-based experiments were conducted. The results of ground based tests and numerical modeling will be presented. Based on numerical modeling, 12 mm 1D silica ampoules were selected. The small diameter ampoule favors closer placement of the baffle to the interface, without excessive radial segregation caused by forced convection while providing more damping of natural convection. The parts in the silica ampoule include 2 carbon springs made by Energy Science Laboratories, Inc., a pyrocarbon-coated graphite cylinder, pyrocarbon-coated graphite a baffle with the shaft and the InSb charge with the seed crystal grown by W.A. Bonner of Crystallod Inc.

Lamellar boundary alignment of DS-processed TiAl-W alloys by a solidification procedure

NASA Astrophysics Data System (ADS)

Jung, In-Soo; Oh, Myung-Hoon; Park, No-Jin; Kumar, K. Sharvan; Wee, Dang-Moon

2007-12-01

In this study, a β solidification procedure was used to align the lamellae in a Ti-47Al-2W (at.%) alloy parallel to the growth direction. The Bridgman technique and the floating zone process were used for directional solidification. The mechanical properties of the directionally solidified alloy were evaluated in tension at room temperature and at 800°C. At a growth rate of 30 mm/h (with the floating zone approach), the lamellae were well aligned parallel to the growth direction. The aligned lamellae yielded excellent room temperature tensile ductility. The tensile yield strength at 800°C was similar to that at room temperature. The orientation of the γ lamellar laths in the directionally solidified ingots, which were manufactured by means of a floating zone process, was identified with the aid of electron backscattered diffraction analysis. On the basis of this analysis, the preferred growth direction of the bcc-β dendrites that formed at high temperatures close to the melting point was inferred to be [001]β at a growth rate of 30 mm/h and [111]β at a growth rate of 90 mm/h.

Fluid mechanics and mass transfer in melt crystal growth: Analysis of the floating zone and vertical Bridgman processes

NASA Technical Reports Server (NTRS)

Brown, R. A.

1986-01-01

This research program focuses on analysis of the transport mechanisms in solidification processes, especially one of interest to the Microgravity Sciences and Applications Program of NASA. Research during the last year has focused on analysis of the dynamics of the floating zone process for growth of small-scale crystals, on studies of the effect of applied magnetic fields on convection and solute segregation in directional solidification, and on the dynamics of microscopic cell formation in two-dimensional solidification of binary alloys. Significant findings are given.

Experiments on Nucleation in Different Flow Regimes

NASA Technical Reports Server (NTRS)

Bayuzick, Robert J.

1999-01-01

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods [1-6]. Dilitometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics [7]. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov [8]. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions.

Experimental investigation of CO2 condensation process using cryogen

NASA Astrophysics Data System (ADS)

Lee, Cheonkyu; Yoo, Junghyun; Lee, Jisung; Park, Hana; Jeong, Sangkwon

2014-01-01

Carbon dioxide (CO2) is one of the dominant gas molecules that causes greenhouse effect, i.e. global warming. Numerous studies have been carried out to regulate the emission of CO2 to reduce greenhouse gas. The liquid CO2 is a convenient form of transportation compared to high-pressurized gaseous CO2. Therefore, the direct liquefaction mechanism of CO2 at low temperature draws technical attention recently. In particular, cold thermal energy of Liquefied Natural Gas (LNG) could be a candidate to condense gaseous CO2, especially in the LNG powered ship. In this paper, the detailed direct condensation process of CO2 using LN2 with intermittent solidification is investigated. Pressurized CO2 at 600 kPa is directly liquefied in a vessel by liquid nitrogen which is supplied into the coiled tube heat exchanger inside the CO2 vessel. The heat exchanger temperature is controlled from 130 K to 205 K to regulate the solidification and sublimation of CO2 by duty control with cryogenic solenoid valve. The characteristics of CO2 condensation process with cryogen are analyzed from the measurement results. The results show that the solidification causes the significant degradation of CO2 condensation heat transfer. Finally, the condensation rate with and without solidification is compared.

The effect of axial crucible rotation on microstructural uniformity during horizontal directional solidification

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Kim, Shinwoo; Woodward, Tracey; Wang, T. G.

1992-01-01

The effects on microstructure of crucible orientation with respect to the earth's gravitational vector, g, during directional solidification of low-volume fraction copper and aluminum, Pb-Cu, and Sn-Al alloys are examined. It is demonstrated that horizontal alignment (i.e. perpendicular to g) in combination with axial rotation of the crucible during growth is sufficient to negate factors which initiate macrosegregation, e.g. density gradients attributed to temperature and/or compositional differences, and promotes a uniform microstructure.

Activities of the Center for the Space Processing of Engineering Materials

NASA Technical Reports Server (NTRS)

1986-01-01

Topics addressed include: containerless processing and purification; directional and rapid solidification; high temperature alloys; oxidation resistant niobium alloys; metallic bonding; effects of solidification mode on structure-property relationships; and dispersion strengthened metal alloys. Each of the projects is reported by company association and follow according to alphabetical order of the company names.

Development of a High Chromium Ni-Base Filler Metal Resistant to Ductility Dip Cracking and Solidification Cracking

NASA Astrophysics Data System (ADS)

Hope, Adam T.

Many nuclear reactor components previously constructed with Ni-based alloys containing 20 wt% Cr have been found to be susceptible to stress corrosion cracking. The nuclear power industry now uses high chromium (˜30wt%) Ni-based filler metals to mitigate stress corrosion cracking. Current alloys are plagued with weldability issues, either solidification cracking or ductility dip cracking (DDC). Solidification cracking is related to solidification temperature range and the DDC is related to the fraction eutectic present in the microstructure. It was determined that an optimal alloy should have a solidification temperature range less than 150°C and at least 2% volume fraction eutectic. Due to the nature of the Nb rich eutectic that forms, it is difficult to avoid both cracking types simultaneously. Through computational modeling, alternative eutectic forming elements, Hf and Ta, have been identified as replacements for Nb in such alloys. Compositions have been optimized through a combination of computational and experimental techniques combined with a design of experiment methodology. Small buttons were melted using commercially pure materials in a copper hearth to obtain the desired compositions. These buttons were then subjected to a gas tungsten arc spot weld. A type C thermocouple was used to acquire the cooling history during the solidification process. The cooling curves were processed using Single Sensor Differential Thermal Analysis to determine the solidification temperature range, and indicator of solidification cracking susceptibility. Metallography was performed to determine the fraction eutectic present, an indicator of DDC resistance. The optimal level of Hf to resist cracking was found to be 0.25 wt%. The optimal level of Ta was found to be 4 wt%. gamma/MC type eutectics were found to form first in all Nb, Ta, and Hf-bearing compositions. Depending on Fe and Cr content, gamma/Laves eutectic was sometimes found in Nb and Ta-bearing compositions, while Hf-bearing compositions had gamma/Ni7Hf2 as the final eutectic to solidify. This study found that the extra Cr in the current generation alloys promotes the gamma/Laves phase eutectic, which expands the solidification temperature range and promotes solidification cracking. Both Ta-bearing and Hf-bearing eutectics were found to solidify at higher temperatures than Nb-bearing eutectics, leading to narrower solidification temperature ranges. Weldability testing on the optimized Ta-bearing compositions revealed good resistance to both DDC and solidification cracking. Unexpectedly, the optimized Hf-bearing compositions were quite susceptible to solidification cracking. This led to an investigation on the possible wetting effect of eutectics on solidification cracking susceptibly, and a theory on how wetting affects the solidification crack susceptibility and the volume fraction of eutectic needed for crack healing has been proposed. Alloys with eutectics that easily wet the grain boundaries have increased solidification crack susceptibility at low volume fraction eutectics, but as the fraction eutectic is increased, experience crack healing at relatively lower fraction eutectics than alloys with eutectics that don't wet as easily. Hf rich eutectics were found to wet grain boundaries significantly more than Nb rich eutectics. Additions of Mo were also found to increase the wetting of eutectics in Nb-bearing alloys.

Study on solidification of immisible alloys (M-10)

NASA Technical Reports Server (NTRS)

Kamio, Akihiko

1993-01-01

Alloying of immiscible alloys under microgravity is of interest in metallurgical processes. Several experiments investigating the alloying of immiscible alloys, such as Al-In, Al-Bi, Zn-Bi, and Zn-Pb, were done in space. Homogeneous distribution of small L2 particles in the matrix, such as an emulsion structure, was expected in the space-solidifed alloys. However, the alloys demonstrated an extremely segregated structure. To date insufficient information was obtained to explain these unexpected results. Our experiment was proposed to clarify the solidification manner of immiscible alloys and to obtain fundamental information concerning structural control of the alloys. In space, density differences between the two liquids separated in immiscible regions can be neglected, so that no sedimentation of L(sub 2) phase will take place. When the growth of the alloys is interrupted and this status is frozen by an adequate rapid cooling procedure, it will provide much information concerning decomposing homogeneous liquid and the interaction between the monotectic growth front morphology and the distribution of L(sub 2) phase. It is anticipated that the results will be useful for elucidating the monotectic solidification manner and it will be instructive to explain the segregated structures obtained in the past space experiments.

Minimizing Segregation during the Controlled Directional Solidification of Dendric Alloys

NASA Technical Reports Server (NTRS)

Grugel, Richard N.; Fedoseyev, Alex; Kim, Shin-Woo

2003-01-01

Gravity-driven convection induced in the liquid by density gradients of temperature or composition disrupts uniform dendritic growth during controlled directional solidification and promotes severe macrosegregation. The solute-rich region about the dendrite tip appears to play a pivotal role in channel initiation. Allen and Hunt referred to this region as an "initial transient" or dynamic region constituting steep concentration gradients. Experimental investigation also point to the role the tip region plays in developing microstructure. Hellawell and co-workers showed that flow-through dendritic channels could be effectively disrupted, and segregation minimized, during the gradient freezing of bulk castings by rotating the melt through a slight angle with respect to Earth's gravity vector. Adapting this principle to controlled directional solidification, it has been shown" that segregation in dendritic alloys can be minimized, and properties improved, by processing the sample near horizontal in conjunction with a slow axial rotation of the crucible. It is postulated that the observed microstructural uniformity arises by maintaining the developing solute field about the dendrite tip. Solute rejected during vertical directional solidification will rise or sink parallel to the primary dendrite arms during axial rotation setting the stage for accumulation, instabilities, and segregation. In contrast, during horizontal growth, the rejected solute will sink or rise perpendicular to the primary dendrite. Now, in the presence of a slight axial rotation, solute that was initially sinking (or rising) will find itself above (or below) its parent dendrite, i.e., still about the tip region. The following is intended to experimentally demonstrate the viability of this concept in coordination with a model that gives predictive insight regarding solute distribution about growing dendrites. Alloys based on the lead-tin eutectic system were used in this study. The system is well characterized, the constituent metals are available in a very pure form, and the thermophysical properties are well known. During solidification of hypoeutectic alloys, e.g., 55 wt pct Pb, the primary dendrites reject the less dense tin, and for the hypereutectic alloys, e.g., 75 wt pct Sn, the primary dendrites reject denser lead. Alloys were prepared by melting appropriate amounts of lead and tin in a glass crucible after which the homogeneous liquid was sucked directly into 5-mm i.d. glass tubes. The sample tube, containing approximately 30 cm of alloy, was then mechanically driven into the directional solidification furnace assembly and positioned such that approx. 20 cm of the sample was remelted. Subsequently, directional solidification was initiated by withdrawing the sample through a water-cooled jacket at a constant growth velocity of 2 ,microns/s. After 5 to 6 cm of growth, the sample was quickly removed from the furnace and quenched in a water bath to preserve the solid-liquid interface. Samples were directionally solidified vertically upward, nearly horizontally, and some in conjunction with an applied axial rotation of the crucible. Temperature gradients at the solid-liquid interface were measured with an in-siru K-type thermocouple. Solidified samples were cut perpendicular and parallel to the growth direction and conventionally prepared for microscopic examination.

Riser Feeding Evaluation Method for Metal Castings Using Numerical Analysis

NASA Astrophysics Data System (ADS)

Ahmad, Nadiah

One of the design aspects that continues to create a challenge for casting designers is the optimum design of casting feeders (risers). As liquid metal solidifies, the metal shrinks and forms cavities inside the casting. In order to avoid shrinkage cavities, risers are added to the casting shape to supply additional molten metal when shrinkage occurs during solidification. The shrinkage cavities in the casting are compensated by controlling the cooling rate to promote directional solidification. This control can be achieved by designing the casting such that the cooling begins at the sections that are farthest away from the risers and ends at the risers. Therefore, the risers will solidify last and feed the casting with the molten metal. As a result, the shrinkage cavities formed during solidification are in the risers which are later removed from the casting. Since casting designers have to usually go through iterative processes of validating the casting designs which are very costly due to expensive simulation processes or manual trials and errors on actual casting processes, this study investigates more efficient methods that will help casting designers utilize their casting experiences systematically to develop good initial casting designs. The objective is to reduce the casting design method iterations; therefore, reducing the cost involved in that design processes. The aim of this research aims at finding a method that can help casting designers design effective risers used in sand casting process of aluminum-silicon alloys by utilizing the analysis of solidification simulation. The analysis focuses on studying the significance of pressure distribution of the liquid metal at the early stage of casting solidification, when heat transfer and convective fluid flow are taken into account in the solidification simulation. The mathematical model of casting solidification was solved using the finite volume method (FVM). This study focuses to improve our understanding of the feeding behavior in aluminum-silicon alloys and the effective feeding by considering the pressure gradient distribution of the molten metal at casting dendrite coherency point. For this study, we will identify the relationship between feeding efficiency, shrinkage behavior and how the change in riser size affects the pressure gradient in the casting. This understanding will be used to help in the design of effective risers.

Kinetic Phase Diagrams of Ternary Al-Cu-Li System during Rapid Solidification: A Phase-Field Study

PubMed Central

Yang, Xiong; Zhang, Lijun; Sobolev, Sergey; Du, Yong

2018-01-01

Kinetic phase diagrams in technical alloys at different solidification velocities during rapid solidification are of great importance for guiding the novel alloy preparation, but are usually absent due to extreme difficulty in performing experimental measurements. In this paper, a phase-field model with finite interface dissipation was employed to construct kinetic phase diagrams in the ternary Al-Cu-Li system for the first time. The time-elimination relaxation scheme was utilized. The solute trapping phenomenon during rapid solidification could be nicely described by the phase-field simulation, and the results obtained from the experiment measurement and/or the theoretical model were also well reproduced. Based on the predicted kinetic phase diagrams, it was found that with the increase of interface moving velocity and/or temperature, the gap between the liquidus and solidus gradually reduces, which illustrates the effect of solute trapping and tendency of diffusionless solidification. PMID:29419753

Solidification Microstructure, Segregation, and Shrinkage of Fe-Mn-C Twinning-Induced Plasticity Steel by Simulation and Experiment

NASA Astrophysics Data System (ADS)

Lan, Peng; Tang, Haiyan; Zhang, Jiaquan

2016-06-01

A 3D cellular automaton finite element model with full coupling of heat, flow, and solute transfer incorporating solidification grain nucleation and growth was developed for a multicomponent system. The predicted solidification process, shrinkage porosity, macrosegregation, grain orientation, and microstructure evolution of Fe-22Mn-0.7C twinning-induced plasticity (TWIP) steel match well with the experimental observation and measurement. Based on a new solute microsegregation model using the finite difference method, the thermophysical parameters including solid fraction, thermal conductivity, density, and enthalpy were predicted and compared with the results from thermodynamics and experiment. The effects of flow and solute transfer in the liquid phase on the solidification microstructure of Fe-22Mn-0.7C TWIP steel were compared numerically. Thermal convection decreases the temperature gradient in the liquid steel, leading to the enlargement of the equiaxed zone. Solute enrichment in front of the solid/liquid interface weakens the thermal convection, resulting in a little postponement of columnar-to-equiaxed transition (CET). The CET behavior of Fe-Mn-C TWIP steel during solidification was fully described and mathematically quantized by grain morphology statistics for the first time. A new methodology to figure out the CET location by linear regression of grain mean size with least-squares arithmetic was established, by which a composition design strategy for Fe-Mn-C TWIP steel according to solidification microstructure, matrix compactness, and homogeneity was developed.

Solidification characteristics and segregation behavior of a P-containing Ni-Fe-Cr-based alloy

NASA Astrophysics Data System (ADS)

Wang, Changshuai; Su, Haijun; Guo, YongAn; Guo, Jianting; Zhou, Lanzhang

2017-09-01

Solidification characteristics and segregation behavior of a P-containing Ni-Fe-Cr-based alloy, considered as boiler and turbine materials in 700 °C advanced ultra-supercritical coal-fired power plants, have been investigated by differential thermal analysis and directional solidification quenching technique. Results reveal that P decreases the solidus temperature, but only has negligible influence on liquidus temperature. After P was added, the solidification sequence has no apparent change, but the width of the mushy zone increases and dendritic structures become coarser. Moreover, P increases the amount and changes the morphology of MC carbide. Energy-dispersive spectroscopy analysis reveals that P has obvious influence on the segregation behavior of the constitute elements with equilibrium partition coefficients (ki) far away from unity, whereas has negligible effect on the constituent elements with ki close to unity and has more influence on the final stage of solidification than at early stage. The distribution profiles reveal that P atoms pile up ahead of the solid/liquid (S/L) interface and strongly segregate to the interdendritic liquid region. The influence of P on solidification characteristics and segregation behavior of Ni-Fe-Cr-based alloy could be attributed to the accumulation of P ahead of the S/L interface during solidification.

Metal Matrix Composites Directionally Solidified

NASA Astrophysics Data System (ADS)

Ares, Alicia Esther; Schvezov, Carlos Enrique

The present work is focus on studying the dendritic solidification of metal matrix composites, MMCs, (using zinc-aluminum, ZA, alloys as matrix and the addition of SiC and Al2O3 particles). The compounds were obtained by as-cast solidification, under continuous stirring and in a second stage were directionally solidified in order to obtain different dendritic growth (columnar, equiaxed and columnar-to-equiaxed transition (CET)). The results in MMCs were compared with those obtained in directional solidification of ZA alloys, primarily with regard to structural parameters. The size and evolution of microstructure, according to the size of the MMCs particles and the variation of the thermal parameters was analyzing. In general it was found that the size of the microstructure (secondary dendritic spacing) decreases with the increase of particles in the matrix. When cooling rate increases, particle size decreases, and a higher cooling rate causes finer and more homogeneous dendrites Also, the segregation which was found in the matrix of the composites was significantly less than in the case of ZA alloys.

Propagative selection of tilted array patterns in directional solidification

NASA Astrophysics Data System (ADS)

Song, Younggil; Akamatsu, Silvère; Bottin-Rousseau, Sabine; Karma, Alain

2018-05-01

We investigate the dynamics of tilted cellular/dendritic array patterns that form during directional solidification of a binary alloy when a preferred-growth crystal axis is misoriented with respect to the temperature gradient. In situ experimental observations and phase-field simulations in thin samples reveal the existence of a propagative source-sink mechanism of array spacing selection that operates on larger space and time scales than the competitive growth at play during the initial solidification transient. For tilted arrays, tertiary branching at the diverging edge of the sample acts as a source of new cells with a spacing that can be significantly larger than the initial average spacing. A spatial domain of large spacing then invades the sample propagatively. It thus yields a uniform spacing everywhere, selected independently of the initial conditions, except in a small region near the converging edge of the sample, which acts as a sink of cells. We propose a discrete geometrical model that describes the large-scale evolution of the spatial spacing profile based on the local dependence of the cell drift velocity on the spacing. We also derive a nonlinear advection equation that predicts the invasion velocity of the large-spacing domain, and sheds light on the fundamental nature of this process. The models also account for more complex spacing modulations produced by an irregular dynamics at the source, in good quantitative agreement with both phase-field simulations and experiments. This basic knowledge provides a theoretical basis to improve the processing of single crystals or textured polycrystals for advanced materials.

Progress in modeling solidification in molten salt coolants

NASA Astrophysics Data System (ADS)

Tano, Mauricio; Rubiolo, Pablo; Doche, Olivier

2017-10-01

Molten salts have been proposed as heat carrier media in the nuclear and concentrating solar power plants. Due to their high melting temperature, solidification of the salts is expected to occur during routine and accidental scenarios. Furthermore, passive safety systems based on the solidification of these salts are being studied. The following article presents new developments in the modeling of eutectic molten salts by means of a multiphase, multicomponent, phase-field model. Besides, an application of this methodology for the eutectic solidification process of the ternary system LiF-KF-NaF is presented. The model predictions are compared with a newly developed semi-analytical solution for directional eutectic solidification at stable growth rate. A good qualitative agreement is obtained between the two approaches. The results obtained with the phase-field model are then used for calculating the homogenized properties of the solid phase distribution. These properties can then be included in a mixture macroscale model, more suitable for industrial applications.

Effect of process parameters on hardness, temperature profile and solidification of different layers processed by direct metal laser sintering (DMLS)

NASA Astrophysics Data System (ADS)

Ahmed, Sazzad Hossain; Mian, Ahsan; Srinivasan, Raghavan

2016-07-01

In DMLS process objects are fabricated layer by layer from powdered material by melting induced by a controlled laser beam. Metallic powder melts and solidifies to form a single layer. Solidification map during layer formation is an important route to characterize micro-structure and grain morphology of sintered layer. Generally, solidification leads to columnar, equiaxed or mixture of these two types grain morphology depending on solidification rate and thermal gradient. Eutectic or dendritic structure can be formed in fully equiaxed zone. This dendritic growth has a large effect on material properties. Smaller dendrites generally increase ductility of the layer. Thus, materials can be designed by creating desired grain morphology in certain regions using DMLS process. To accomplish this, hardness, temperature distribution, thermal gradient and solidification cooling rate in processed layers will be studied under change of process variables by using finite element analysis, with specific application to Ti-6Al-4V.

Coupled Heat Transfer and Fluid Dynamics Modeling of InSb Solidification

NASA Astrophysics Data System (ADS)

Barvinschi, Paul; Barvinschi, Floricica

2011-10-01

A method for the directional solidification of melted InSb in a silica ampoule is presented and solved with COMSOL Multiphysics. The configuration and initial boundary settings of the model resemble those used in a de-wetting vertical Bridgman configuration [1]. A slightly modified version of the method presented by Voller and Prakash [2] is used to account for solidification of the liquid phase, including convection and conduction heat transfer with mushy region phase change. Axial-symmetric numerical simulations of temperature and velocity fields, under normal gravity, are carried out using different thermal conditions.

Interferometric measurements of a dendritic growth front solutal diffusion layer

NASA Technical Reports Server (NTRS)

Hopkins, John A.; Mccay, T. D.; Mccay, Mary H.

1991-01-01

An experimental study was undertaken to measure solutal distributions in the diffusion layer produced during the vertical directional solidification (VDS) of an ammonium chloride - water (NH4Cl-H2O) solution. Interferometry was used to obtain concentration measurements in the 1-2 millimeter region defining the diffusion layer. These measurements were fitted to an exponential form to extract the characteristic diffusion parameter for various times after the start of solidification. The diffusion parameters are within the limits predicted by steady state theory and suggest that the effective solutal diffusivity is increasing as solidification progresses.

Solidification processing of intermetallic Nb-Al alloys

NASA Technical Reports Server (NTRS)

Smith, Preston P.; Oliver, Ben F.; Noebe, Ronald D.

1992-01-01

Several Nb-Al alloys, including single-phase NbAl3 and the eutectic of Nb2Al and NbAl3, were prepared either by nonconsumable arc melting in Ar or by zone processing in He following initial induction melting and rod casting, and the effect of the solidification route on the microstructure and room-temperature mechanical properties of these alloys was investigated. Automated control procedures and melt conditions for directional solidification of NbAl3 and the Nb2Al/Nb3Al eutectic were developed; high purity and stoichiometry were obtained. The effects of ternary additions of Ti and Ni are described.

Transient experiments with thermite melts for a core catcher concept based on water addition from below

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tromm, W.; Alsmeyer, H.

1995-09-01

A core catcher concept is proposed to be integrated into a new pressurized water reactor. The core catcher achieves coolability by spreading and fragmentation of the ex-vessel core melt based on a process of water inlet from the bottom through the melt. By highly effective heat removal that uses evaporating water in direct contact with the fragmented melt, the corium melt would solidify in a short time period, and long-term cooling could be maintained by continuous water evaporation from the flooded porous or fragmented corium bed. The key process for obtaining coolability is the coupling of the three effects: (a)more » water ingression from below and its evaporation, (b) break up and fragmentation of the corium layer, and (c) heat transfer and solidification of the let. These mechanisms are investigated in transient medium-scale experiments with thermite melts. The experimental setup represents a section of the proposed core catcher design. A thermite melt is located on the core catcher plate with a passive water supply from the bottom. After generation of the melt, the upper sacrificial layer is eroded until water penetrates into the melt for the bottom through plugs in the supporting plate. Fragmentation and fast solidification of the melt are observed, and long-term heat removal is guaranteed by the coolant water flooding the porous melt. Water inflow is sufficient to safely remove the decay heat in a comparable corium layer. The open porosity is created by the vapor streaming through the melt during the solidification process. Fracture of the solid by thermomechanical stresses is not observed. The experiments in their current stage show the principal feasibility of the proposed cooling concept and are used to prepare large-scale experiments to be performed in the modified BETA facility with sustained heating of the melt.« less

The study of dopant segregation behavior during the growth of GaAs in microgravity

NASA Technical Reports Server (NTRS)

Matthiesen, David H.; Majewski, J. A.

1994-01-01

An investigation into the segregation behavior of selenium doped gallium arsenide during directional solidification in the microgravity environment was conducted using the Crystal Growth Furnace (CGF) aboard the first United States Microgravity Laboratory (USML-1). The two crystals grown were 1.5 cm in diameter and 16.5 cm in length with an initial melt length of 14 cm. Two translation periods were executed, the first at 2.5 microns/s and after a specified time, which was different between the two experiments, the translation rate was doubled to 5.0 microns/s. The translation was then stopped and the remaining sample melt was solidified using a gradient freeze technique in the first sample and a rapid solidification in the second experiment. Measurement of the selenium dopant distribution, using quantitative infrared transmission imaging, indicates that the first sample initially achieved diffusion controlled growth as desired. However, after about 1 cm of growth, the segregation behavior was driven from a diffusion controlled growth regime to a complete mixing regime. Measurements in the second flight sample indicated that the growth was always in a complete mixing regime. In both experiments, voids in the center line of the crystal, indicative of bubble entrapment, were found to correlate with the position in the crystal when the translation rates were doubled.

Bubble Formation and Transport during Microgravity Materials Processing: Model Experiments on the Space Station

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Anilkumar, A. V.; Lee, C. P.

2003-01-01

Flow Visualization experiments on the controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The experimental samples were prepared on ground by filling glass tubes, 1 cm ID and approximately 30 cm in length, with pure succinonitrile (SCN) under 450 millibar of nitrogen. Porosity in the samples arose from natural shrinkage, and in some cases by direct insertion of nitrogen bubbles, during solidification of the liquid SCN. The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus that is placed in the glovebox facility (GBX) aboard the ISS. Experimental processing parameters of temperature gradient and translation speed, as well as camera settings, were remotely monitored and manipulated from the ground Telescience Center (TSC) at the Marshall Space Flight Center. During the experiments, the sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. The temperatures in the sample are monitored by six in situ thermocouples. Real time visualization of the controlled directional melt back shows bubbles of different sizes initiating at the melt interface and, upon dislodging from the melting solid, migrating at different speeds into the temperature field ahead of them, before coming to rest. The thermocapillary flow field set up in the melt, ahead of the interface, is dramatic in the context of the large bubbles, and plays a major role in dislodging the bubble. A preliminary analysis of the observed bubble formation and mobility during melt back and its implication to future microgravity experiments is presented and discussed.

Bubble Formation and Transport during Microgravity Materials Processing: Model Experiments on the International Space Station

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Anilkumar, A. V.; Lee, C. P.

2003-01-01

Flow Visualization experiments on the controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The experimental samples were prepared on ground by filling glass tubes, 1 cm ID and approximately 30 cm in length, with pure succinonitrile (SCN) under 450 millibar of nitrogen. Porosity in the samples arose from natural shrinkage, and in some cases by direct insertion of nitrogen bubbles, during solidification of the liquid SCN. The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus that is placed in the glovebox facility (GBX) aboard the ISS. Experimental processing parameters of temperature gradient and translation speed, as well as camera settings, were remotely monitored and manipulated from the ground Telescience Center (TSC) at the Marshall Space Flight Center. During the experiments, the sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. The temperatures in the sample are monitored by six in situ thermocouples. Real time visualization of the controlled directional melt back shows bubbles of different sizes initiating at the melt interface and, upon dislodging from the melting solid, migrating at different speeds into the temperature field ahead of them, before coming to rest. The thermocapillary flow field set up in the melt, ahead of the interface, is dramatic in the context of the large bubbles, and plays a major role in dislodging the bubble. A preliminary analysis of the observed bubble formation and mobility during melt back and its implication to future microgravity experiments is presented and discussed.

A Real Time Investigation of Morphological Evolution During Solidification of Different Alloy Systems

NASA Technical Reports Server (NTRS)

Sen, S.; Kaukler, W. F.; Curreri, P. A.

1999-01-01

Solidification phenomenon which occur at the solid/liquid (s/I) interface play a major role in the determination of structure and hence the technologically important properties of a casting. However, metals being opaque, conclusions related to several important phenomenon such as boundary layer thickness, morphological evolution, and eutectic and cell spacing are deduced from quenching experiments and subsequent post solidification metallographic analysis. Consequently, limited information is obtained about the dynamics of the process. This paper will discuss the recent efforts at the Space Science Laboratory, NASA Marshall Space Flight Center, to view and quantify in-situ and in real time the dynamics of the solidification process and to measure interfacial undercooling. First, a high resolution x-ray transmission microscope (XTM) has been developed to monitor fundamental interfacial phenomena during directional solidification of metals and alloys. The XTM operates in the range of 10-100 KeV and through projection is capable of achieving magnification of up to 16OX. Secondly, an innovative collapsible furnace has been designed to quantify interfacial undercooling by measuring the temperature of a moving s/I interface in reference to a fixed s/l interface. This measurement technique is non-intrusive in nature and is based on the Seebeck principle. In this paper real time results obtained to characterize the dynamics of irregular eutectic spacing will be presented. As an example fiber to lamella or plate transition in the Al-Al2Au eutectic system will be discussed. Further, a resolution limit of 25 micron has permitted viewing in real time morphological instability and cellular growth in Al-Au and Al-Ag systems. Simultaneously, a systematic investigation has been carried out to measure interfacial undercooling for Pb-1 wt.% Sn at and near the marginal stability regime. In conjunction with the XTM observations this study attempts to validate existing relationships between undercooling and growth velocity during plane front growth, marginal stability regime, and stable cellular growth.

Effects of N/C Ratio on Solidification Behaviors of Novel Nb-Bearing Austenitic Heat-Resistant Cast Steels for Exhaust Components of Gasoline Engines

NASA Astrophysics Data System (ADS)

Zhang, Yinhui; Li, Mei; Godlewski, Larry A.; Zindel, Jacob W.; Feng, Qiang

2017-03-01

In order to comply with more stringent environmental and fuel consumption regulations, novel Nb-bearing austenitic heat-resistant cast steels that withstand exhaust temperatures as high as 1,323 K (1,050 °C) is urgently demanded from automotive industries. In the current research, the solidification behavior of these alloys with variations of N/C ratio is investigated. Directional solidification methods were carried out to examine the microstructural development in mushy zones. Computational thermodynamic calculations under partial equilibrium conditions were performed to predict the solidification sequence of different phases. Microstructural characterization of the mushy zones indicates that N/C ratio significantly influenced the stability of γ-austenite and the precipitation temperature of NbC/Nb(C,N), thereby altering the solidification path, as well as the morphology and distribution of NbC/Nb(C,N) and γ-ferrite. The solidification sequence of different phases predicted by thermodynamic software agreed well with the experimental results, except the specific precipitation temperatures. The generated data and fundamental understanding will be helpful for the application of computational thermodynamic methods to predict the as-cast microstructure of Nb-bearing austenitic heat-resistant steels.

Interface Pattern Selection in Directional Solidification

NASA Technical Reports Server (NTRS)

Trivedi, Rohit; Tewari, Surendra N.

2001-01-01

The central focus of this research is to establish key scientific concepts that govern the selection of cellular and dendritic patterns during the directional solidification of alloys. Ground-based studies have established that the conditions under which cellular and dendritic microstructures form are precisely where convection effects are dominant in bulk samples. Thus, experimental data can not be obtained terrestrially under pure diffusive regime. Furthermore, reliable theoretical models are not yet possible which can quantitatively incorporate fluid flow in the pattern selection criterion. Consequently, microgravity experiments on cellular and dendritic growth are designed to obtain benchmark data under diffusive growth conditions that can be quantitatively analyzed and compared with the rigorous theoretical model to establish the fundamental principles that govern the selection of specific microstructure and its length scales. In the cellular structure, different cells in an array are strongly coupled so that the cellular pattern evolution is controlled by complex interactions between thermal diffusion, solute diffusion and interface effects. These interactions give infinity of solutions, and the system selects only a narrow band of solutions. The aim of this investigation is to obtain benchmark data and develop a rigorous theoretical model that will allow us to quantitatively establish the physics of this selection process.

Macrosegregation during plane front directional solidification of Csl-1 wt. percent Tll alloy

NASA Technical Reports Server (NTRS)

Sidawi, I. M. S.; Tewari, S. N.

1991-01-01

Macrosegregation produced during vertical Bridgeman directional solidification of Csl-1 wt. pct. Tll in crucibles of varying diameter, from 0.5 to 2.0 cm, was examined. Gravity driven convection is present in the melt even in the smallest crucible diameter of 0.5 cm. Observed solutal profiles are in agreement with the analytical boundary layer model of Favier which describes macrosegregation in the presence of convection. The scintillation efficiency of Csl decreases along the specimen length as the thallium iodide content of the alloy increases.

Solidification in direct metal deposition by LENS processing

NASA Astrophysics Data System (ADS)

Hofmeister, William; Griffith, Michelle

2001-09-01

Thermal imaging and metallographic analysis were used to study Laser Engineered Net Shaping (LENS™) processing of 316 stainless steel and H13 tool steel. The cooling rates at the solid-liquid interface were measured over a range of conduction conditions. The length scale of the molten zone controls cooling rates during solidification in direct metal deposition. In LENS processing, the molten zone ranges from 0.5 mm in length to 1.5 mm, resulting in cooling rates at the solid-liquid interface ranging from 200 6,000 Ks-1.

Experimental investigation of CO{sub 2} condensation process using cryogen

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lee, Cheonkyu; Yoo, Junghyun; Lee, Jisung

2014-01-29

Carbon dioxide (CO{sub 2}) is one of the dominant gas molecules that causes greenhouse effect, i.e. global warming. Numerous studies have been carried out to regulate the emission of CO{sub 2} to reduce greenhouse gas. The liquid CO{sub 2} is a convenient form of transportation compared to high-pressurized gaseous CO{sub 2}. Therefore, the direct liquefaction mechanism of CO{sub 2} at low temperature draws technical attention recently. In particular, cold thermal energy of Liquefied Natural Gas (LNG) could be a candidate to condense gaseous CO{sub 2}, especially in the LNG powered ship. In this paper, the detailed direct condensation process ofmore » CO{sub 2} using LN{sub 2} with intermittent solidification is investigated. Pressurized CO{sub 2} at 600 kPa is directly liquefied in a vessel by liquid nitrogen which is supplied into the coiled tube heat exchanger inside the CO{sub 2} vessel. The heat exchanger temperature is controlled from 130 K to 205 K to regulate the solidification and sublimation of CO{sub 2} by duty control with cryogenic solenoid valve. The characteristics of CO{sub 2} condensation process with cryogen are analyzed from the measurement results. The results show that the solidification causes the significant degradation of CO{sub 2} condensation heat transfer. Finally, the condensation rate with and without solidification is compared.« less

Ice Layer Spreading along a Solid Substrate during Solidification of Supercooled Water: Experiments and Modeling.

PubMed

Schremb, Markus; Campbell, James M; Christenson, Hugo K; Tropea, Cameron

2017-05-16

The thermal influence of a solid wall on the solidification of a sessile supercooled water drop is experimentally investigated. The velocity of the initial ice layer propagating along the solid substrate prior to dendritic solidification is determined from videos captured using a high-speed video system. Experiments are performed for varying substrate materials and liquid supercooling. In contrast to recent studies at moderate supercooling, in the case of metallic substrates only a weak influence of the substrate's thermal properties on the ice layer velocity is observed. Using the analytical solution of the two-phase Stefan problem, a semiempirical model for the ice layer velocity is developed. The experimental data are well described for all supercooling levels in the entire diffusion limited solidification regime. For higher supercooling, the model overestimates the freezing velocity due to kinetic effects during molecular attachment at the solid-liquid interface, which are not accounted for in the model. The experimental findings of the present work offer a new perspective on the design of anti-icing systems.

The preferential orientation and lattice misfit of the directionally solidified Fe-Al-Ta eutectic composite

NASA Astrophysics Data System (ADS)

Cui, Chunjuan; Wang, Pei; Yang, Meng; Wen, Yagang; Ren, Chiqiang; Wang, Songyuan

2018-01-01

Fe-Al intermetallic compound has been paid more attentions recently in many fields such as aeronautic, aerospace, automobile, energy and chemical engineering, and so on. In this paper Fe-Al-Ta eutectic was prepared by a modified Bridgman directional solidification technique, and it is found that microstructure of the Fe-Al-Ta eutectic alloy transforms from the broken-lamellar eutectic to cellular eutectic with the increase of the solidification rate. In the cellular eutectic structure, the fibers are parallel to each other within the same grain, but some fibers are deviated from the original orientation at the grain boundaries. To study the crystallographic orientation relationship (OR) between the two phases, the preferential orientation of the Fe-Al-Ta eutectic alloy at the different solidification rates was studied by Selected Area Electron Diffraction (SAED). Moreover, the lattice misfit between Fe2Ta(Al) Laves phase and Fe(Al,Ta) matrix phase was calculated.

Gravitational modulation of thermosolutal convection during directional solidification

NASA Astrophysics Data System (ADS)

Murray, B. T.; Coriell, S. R.; McFadden, G. B.; Wheeler, A. A.; Saunders, B. V.

1993-03-01

During directional solidification of a binary alloy at constant velocity, thermosolutal convection may occur due to the temperature and solute gradients associated with the solidification process. For vertical growth in an ideal furnace (lacking horizontal gradients) a quiescent state is possible. The effect of a time-periodic vertical gravitational acceleration (or equivalently vibration) on the onset of thermosolutal convection is calculated based on linear stability using Floquet theory. Numerical calculations for the onset of instability have been carried out for a semiconductor alloy with Schmidt number of 10 and Prandtl number of 0.1 with primary emphasis on large modulation frequencies in a microgravity environment for which the background gravitational acceleration is negligible. The numerical results demonstrate that there is a significant difference in stability depending on whether a heavier or lighter solute is rejected. For large modulation frequencies, the stability behavior can be described by either the method of averaging or an asymptotic resonant mode analysis.

Numerical Simulation and Experimental Casting of Nickel-Based Single-Crystal Superalloys by HRS and LMC Directional Solidification Processes

NASA Astrophysics Data System (ADS)

Yan, Xuewei; Wang, Run'nan; Xu, Qingyan; Liu, Baicheng

2017-04-01

Mathematical models for dynamic heat radiation and convection boundary in directional solidification processes are established to simulate the temperature fields. Cellular automaton (CA) method and Kurz-Giovanola-Trivedi (KGT) growth model are used to describe nucleation and growth. Primary dendritic arm spacing (PDAS) and secondary dendritic arm spacing (SDAS) are calculated by the Ma-Sham (MS) and Furer-Wunderlin (FW) models respectively. The mushy zone shape is investigated based on the temperature fields, for both high-rate solidification (HRS) and liquid metal cooling (LMC) processes. The evolution of the microstructure and crystallographic orientation are analyzed by simulation and electron back-scattered diffraction (EBSD) technique, respectively. Comparison of the simulation results from PDAS and SDAS with experimental results reveals a good agreement with each other. The results show that LMC process can provide both dendritic refinement and superior performance for castings due to the increased cooling rate and thermal gradient.

Macrosegregation Caused by Convection Associated with Directional Solidification through Cross-Section Change

NASA Technical Reports Server (NTRS)

Ghods, M.; Lauer, M.; Tewari, S. N.; Poirier, D. R..; Grugel, R. N.

2015-01-01

Al-7 wt% Si and Pb-6 wt% Sb alloy samples were directionally solidified (DS), with liquid above and solid below and gravity pointing down, in cylindrical graphite crucibles through an abrupt cross-section change. Fraction eutectic distribution in the microstructure, primary dendrite spacing and primary dendrite trunk diameters have been measured in the DS samples in the vicinity of section change in order to examine the effect of convection associated with the combined influence of thermosolutal factors and solidification shrinkage. It is observed that convection not only produces extensive radial and axial macrosegregation near cross-section change, it also affects the dendritic array morphology. Primary dendrite spacing and primary dendrite trunk diameter, both, are influenced by this convection. In addition to the experimental results, preliminary results from a numerical model which includes solidification shrinkage and thermosolutal convection in the mushy zone in its analysis will also be presented

Analytical description of the ternary melt and solution crystallization with a non-linear phase diagram

NASA Astrophysics Data System (ADS)

Toropova, L. V.; Alexandrov, D. V.

2018-05-01

The directional solidification of a ternary system with an extended phase transition region is theoretically studied. A mathematical model is developed to describe quasi-stationary solidification, and its analytical solution is constructed with allowance for a nonlinear liquids line equation. We demonstrate that the phase diagram nonlinearity leads to substantial changes of analytical solutions.

SolTrack: an automatic video processing software for in situ interface tracking.

PubMed

Griesser, S; Pierer, R; Reid, M; Dippenaar, R

2012-10-01

High-Resolution in situ observation of solidification experiments has become a powerful technique to improve the fundamental understanding of solidification processes of metals and alloys. In the present study, high-temperature laser-scanning confocal microscopy (HTLSCM) was utilized to observe and capture in situ solidification and phase transformations of alloys for subsequent post processing and analysis. Until now, this analysis has been very time consuming as frame-by-frame manual evaluation of propagating interfaces was used to determine the interface velocities. SolTrack has been developed using the commercial software package MATLAB and is designed to automatically detect, locate and track propagating interfaces during solidification and phase transformations as well as to calculate interfacial velocities. Different solidification phenomena have been recorded to demonstrate a wider spectrum of applications of this software. A validation, through comparison with manual evaluation, is included where the accuracy is shown to be very high. © 2012 The Authors Journal of Microscopy © 2012 Royal Microscopical Society.

Convection and macrosegregation in Al-19Cu alloy directionally solidified through an abrupt contraction in cross-section: A comparison with Al-7Si

NASA Astrophysics Data System (ADS)

Ghods, M.; Lauer, M.; Grugel, R. N.; Tewari, S. N.; Poirier, D. R.

2017-02-01

Hypoeutectic Al-19 wt. % Cu alloys were directionally solidified in cylindrical molds that featured an abrupt cross-section decrease 9.5 to 3.2 mm in diameter). Thermo-solutal convection and cross-section-change-induced shrinkage flow effects on macrosegregation were investigated. Dendrite clustering and extensive radial macrosegregation was seen, particularly in the larger cross-section before contraction. This alloy shows positive longitudinal macrosegregation near the contraction followed by negative macrosegregation right after it; the extent of macrosegregation, however, decreases with increasing growth speed. The degree of thermo-solutal convection was compared to another study investigating directional solidification of Al-7 wt. % Si [1] in order to study the effect of solutal expansion coefficient on macrosegregation. An interesting change of the radial macrosegregation profile, attributable to the area-change-induced-shrinkage flow, was observed very close to the contraction. A two-dimensional model accounting for both shrinkage and thermo-solutal convection was used to simulate solidification, the resulting steepling as well as axial and radial macrosegregation. The experimentally observed macrosegregation associated with the contraction during directional solidification was well predicted by the numerical simulations.

Real Time Characterization of Solid/Liquid Interfaces During Directional Solidification

NASA Technical Reports Server (NTRS)

Sen, S.; Kaukler, W. K.; Curreri, P. A.; Peters, P.

1997-01-01

A X-Ray Transmission Microscope (XTM) has been developed to observe in real time and in-situ solidification phenomenon at the solid/liquid interface. Recent improvements in the horizontal Bridgman furnace design provides real-time magnification (during solidification) up to 12OX. The increased magnification has enabled for the first time the XTM imaging of real-time growth of fibers and particles with diameters of 3-6 micrometers. Further, morphological transitions from planar to cellular interfaces have also been imaged. Results from recent XTM studies on Al-Bi monotectic system, Al-Au eutectic system and interaction of insoluble particles with s/I interfaces in composite materials will be presented. An important parameter during directional solidification of molten metal is the interfacial undercooling. This parameter controls the morphology and composition at the s/I interface. Conventional probes such as thermocouples, due to their large bead size, do not have sufficient resolution for measuring undercooling at the s/I interface. Further, the intrusive nature of the thermocouples also distorts the thermal field at the s/I interface. To overcome these inherent problems we have recently developed a compact furnace which utilizes a non-intrusive technique (Seebeck) to measure undercooling at the S/I interface. Recent interfacial undercooling measurements obtained for the Pb-Sn system will be presented. The Seebeck measurement furnace in the future will be integrated with the XTM to provide the most comprehensive tool for real time characterization of s/I interfaces during solidification.

Convection effects on Skylab experiments M551, M552, and M553, phase C report. [metal melting, exothermic brazing, and sphere forming under weightless conditions

NASA Technical Reports Server (NTRS)

Bourgeois, S. V.

1973-01-01

This report described an analysis of Skylab Experiments M551 (Metals Melting), M552 (Exothermic Brazing), and M553 (Sphere Forming). The primary objective is the study of convection in the molten metals and their attendant solidification theory. Particular attention is given to clarifying the effects of reduced gravity on molten metal flow and solidification. Based on an analysis of physical forces and solidification theory expected for ground-based and Skylab processing, low-g variations were predicted for each experiment. A comparison was then made with the Skylab results available to date. Both metallurgical analyses of other investigators and movies of ground-based and Skylab samples were utilized. Several low-g variations in Skylab processed materials were successfully predicted based on expected variations in physical forces and fluid convection. The same analysis also successfully predicted several features in the Skylab-processed materials which were identical to terrestrially-processed materials. These results are summarized in the conclusion section for each experiment.

Numerical simulation of controlled directional solidification under microgravity conditions

NASA Astrophysics Data System (ADS)

Holl, S.; Roos, D.; Wein, J.

The computer-assisted simulation of solidification processes influenced by gravity has gained increased importance during the previous years regarding ground-based as well as microgravity research. Depending on the specific needs of the investigator, the simulation model ideally covers a broad spectrum of applications. These primarily include the optimization of furnace design in interaction with selected process parameters to meet the desired crystallization conditions. Different approaches concerning the complexity of the simulation models as well as their dedicated applications will be discussed in this paper. Special emphasis will be put on the potential of software tools to increase the scientific quality and cost-efficiency of microgravity experimentation. The results gained so far in the context of TEXUS, FSLP, D-1 and D-2 (preparatory program) experiments, highlighting their simulation-supported preparation and evaluation will be discussed. An outlook will then be given on the possibilities to enhance the efficiency of pre-industrial research in the Columbus era through the incorporation of suitable simulation methods and tools.

Measurements of microhardness during transient horizontal directional solidification of Al-Rich Al-Cu alloys: Effect of thermal parameters, primary dendrite arm spacing and Al2Cu intermetallic phase

NASA Astrophysics Data System (ADS)

Barros, André Santos; Magno, Igor Alexsander; Souza, Fabrício Andrade; Mota, Carlos Alberto; Moreira, Antonio Luciano; Silva, Maria Adrina; Rocha, Otávio Lima

2015-05-01

In this work, the effect of the growth rate (VL) and cooling rate (TR), primary dendritic arm spacing (λ1) and Al2Cu intermetallic phase on the microhardness was investigated during transient horizontal directional solidification of Al-3wt%Cu and Al-8wt%Cu alloys. Microstructural characterization of the investigated alloys was performed using traditional techniques of metallography, optical and SEM microscopy and X-Ray diffraction. The microhardness evolution as a function of the thermal and microstructural parameters (VL, TR, and λ1) was evaluated using power and Hall-Petch type experimental laws, which were compared with other laws in the literature. In order to examine the effect of the Al2Cu intermetallic phase, microhardness measurements were performed in interdendritic regions. Finally, a comparative analysis was performed between the experimental data of this work and theoretical models from the literature that have been proposed to predict primary dendrite arm spacing, which have been tested in numerous works considering upward directional solidification.

Adaptive-Grid Methods for Phase Field Models of Microstructure Development

NASA Technical Reports Server (NTRS)

Dantzig, Jonathan A.; Goldenfeld, Nigel

2001-01-01

Modeling solidification microstructures has become an area of intense study in recent years. The properties of large scale cast products, ranging from automobile engine blocks to aircraft components and other industrial applications, are strongly dependent on the physics that occur at the mesoscopic and microscopic length scales during solidification. The predominant morphology found in solidification microstructures is the dendrite, a tree-like pattern of solid around which solidification proceeds. The microscopic properties of cast products are determined by the length scales of these dendrites, and their associated segregation profiles. For this reason understanding the mechanisms for pattern selection in dendritic growth has attracted a great deal of interest from the experimental and theoretical communities. In particular, a great deal of research has been undertaken to understand such issues as dendrite morphology, shape and growth speed. Experiments on dendrite evolution in pure materials by Glicksman and coworkers on succinonitrile (SCN), and more recently pivalic acid (PVA), as well as other transparent analogs of metals, have provided tests of theories for dendritic growth, and have stimulated considerable theoretical progress. These experiments have clearly demonstrated that in certain parameter ranges the physics of the dendrite tip can be characterized by a steady value for the dendrite tip velocity, radius of curvature and shape. Away from the tip, the time-dependent dendrite exhibits a characteristic sidebranching as it propagates, which is not yet well understood. These experiments are performed by observing individual dendrites growing into an undercooled melt. The experiments are characterized by the dimensionless undercooling. Most experiments are performed at low undercooling.

Quasi-Steady Acceleration Direction Indicator in Three Dimensions

NASA Technical Reports Server (NTRS)

DeLombard, Richard; Nelson, Emily S.; Jules, Kenol

2000-01-01

Many materials processing and fluids physics experiments conducted in a microgravity environment require knowledge of the orientation of the low-frequency acceleration vector. This need becomes especially acute for space experiments such as directional solidification of a molten semiconductor, which is extremely sensitive to orientation and may involve tens of hours of operations of a materials furnace. These low-frequency acceleration data have been measured for many Shuttle missions with the Orbital Acceleration Research Experiment. Previous attempts at using fluid chambers for acceleration measurements have met with limited success due to pointing and vehicle attitude complications. An acceleration direction indicator is described, which is comprised of two orthogonal short cylinders of fluid, each with a small bubble. The motion and the position of the bubble within the chamber will indicate the direction of the acceleration experienced at the sensor location. The direction of the acceleration vector may then be calculated from these data. The frequency response of such an instrument may be tailored for particular experiments with the proper selection of fluid and gas parameters, surface type, and geometry. A three-dimensional system for sensing and displaying the low-frequency acceleration direction via an innovative technique described in this paper has advantages in terms of size, mass, and power compared with electronic instrumentation systems.

Growth of CdZnTe Crystals for Radiation Detector Applications by Directional Solidification

NASA Technical Reports Server (NTRS)

Su, Ching-Hua

2014-01-01

Advances in Cadmium Zinc Telluride (Cd(sub 1-x)Zn(sub x)Te) growth techniques are needed for the production of large-scale arrays of gamma and x-ray astronomy. The research objective is to develop crystal growth recipes and techniques to obtain large, high quality CdZnTe single crystal with reduced defects, such as charge trapping, twinning, and tellurium precipitates, which degrade the performance of CdZnTe and, at the same time, to increase the yield of usable material from the CdZnTe ingot. A low gravity material experiment, "Crystal Growth of Ternary Compound Semiconductors in Low Gravity Environment", will be performed in the Material Science Research Rack (MSRR) on International Space Station (ISS). One section of the flight experiment is the melt growth of CdZnTe ternary compounds. This talk will focus on the ground-based studies on the growth of Cd(sub 0.80)Zn(sub 0.20)Te crystals for radiation detector applications by directional solidification. In this investigation, we have improved the properties that are most critical for the detector applications (electrical properties and crystalline quality): a) Electrical resistivity: use high purity starting materials (with reproducible impurity levels) and controlled Cd over pressure during growth to reproducibly balance the impurity levels and Cd vacancy concentration b) Crystalline quality: use ultra-clean growth ampoule (no wetting after growth), optimized thermal profile and ampoule design, as well as a technique for supercool reduction to growth large single crystal with high crystalline quality

Solidification Using the Baffle in Sealed Ampoules

NASA Technical Reports Server (NTRS)

Ostrogorsky, A.; Marin, C.; Churilov, A.; Volz, M. P.; Bonner, W. A.; Spivey, R. A.; Smith, G.

2003-01-01

Solidification Using a Baffle in Sealed Ampoules (SUBSA) is the first investigation conducted in the Microgravity Science Glovebox (MSG) Facility at the International Space Station (ISS) Alpha. In July, August and September of 2002, 8 single crystals of InSb, doped with Te and Zn, were directionally solidified in microgravity. Ground based tests, related numerical modeling and images of the growth process obtained in microgravity are presented.

Overview of the Tusas Code for Simulation of Dendritic Solidification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Trainer, Amelia J.; Newman, Christopher Kyle; Francois, Marianne M.

2016-01-07

The aim of this project is to conduct a parametric investigation into the modeling of two dimensional dendrite solidification, using the phase field model. Specifically, we use the Tusas code, which is for coupled heat and phase-field simulation of dendritic solidification. Dendritic solidification, which may occur in the presence of an unstable solidification interface, results in treelike microstructures that often grow perpendicular to the rest of the growth front. The interface may become unstable if the enthalpy of the solid material is less than that of the liquid material, or if the solute is less soluble in solid than itmore » is in liquid, potentially causing a partition [1]. A key motivation behind this research is that a broadened understanding of phase-field formulation and microstructural developments can be utilized for macroscopic simulations of phase change. This may be directly implemented as a part of the Telluride project at Los Alamos National Laboratory (LANL), through which a computational additive manufacturing simulation tool is being developed, ultimately to become part of the Advanced Simulation and Computing Program within the U.S. Department of Energy [2].« less

Transport processes in directional solidification and their effects on microstructure development

NASA Astrophysics Data System (ADS)

Mazumder, Prantik

The processing of materials with unique electronic, mechanical, optical and thermal properties plays a crucial role in modern technology. The quality of these materials depend strongly on the microstructures and the solute/dopant fields in the solid product, that are strongly influenced by the intricate coupling of heat and mass transfer and melt flow in the growth systems. An integrated research program is developed that include precisely characterized experiments and detailed physical and numerical modeling of the complex transport and dynamical processes. Direct numerical simulation of the solidification process is carried out that takes into account the unsteady thermo-solutal convection in the vertical Bridgman crystal growth system, and accurately models the thermal interaction between the furnace and the ampoule by appropriately using experimentally measured thermal profiles. The flow instabilities and transitions and the nonlinear evolution following the transitions are investigated by time series and flow pattern analysis. A range of complex dynamical behavior is predicted with increasing thermal Rayleigh number. The route to chaos appears as: steady convection --> transient mono-periodic --> transient bi-periodic --> transient quasiperiodic --> transient intermittent oscillation- relaxation --> stable intermittent oscillation-relaxation attractor. The spatio-temporal dynamics of the melt flow is found to be directly related to the spatial patterns observed experimentally in the solidified crystals. The application of the model to two phase Sn-Cd peritectic alloys showed that a new class of tree-like oscillating microstructure develops in the solid phase due to unsteady thermo-solutal convection in the liquid melt. These oscillating layered structures can give the illusion of band structures on a plane of polish. The model is applied to single phase solidification in the Al-Cu and Pb-Sn systems to characterize the effect of convection on the macroscopic shape and disorder in the primary arm spacing of the cellular/dendritic freezing front. The apparently puzzling experimental observation of higher disorder in the weakly convective Al-Cu system than that in the highly convective Pb-Sn system is explained by the numerical calculations.

Segregation effects during solidification in weightless melts. [effects of evaporation and solidification on crystalization

NASA Technical Reports Server (NTRS)

Li, C.

1975-01-01

Computer programs are developed and used in the study of the combined effects of evaporation and solidification in space processing. The temperature and solute concentration profiles during directional solidification of binary alloys with surface evaporation were mathematically formulated. Computer results are included along with an econotechnical model of crystal growth. This model allows: prediction of crystal size, quality, and cost; systematic selection of the best growth equipment or alloy system; optimization of growth or material parameters; and a maximization of zero-gravity effects. Segregation in GaAs crystals was examined along with vibration effects on GaAs crystal growth. It was found that a unique segregation pattern and strong convention currents exist in GaAs crystal growth. Some beneficial effects from vibration during GaAs growth were discovered. The implications of the results in space processing are indicated.

Pattern selection in solidification

NASA Technical Reports Server (NTRS)

Langer, J. S.

1984-01-01

Directional solidification of alloys produces a wide variety of cellular or lamellar structures which, depending upon growth conditions, may be reproducibly regular or may behave chaotically. It is not well understood how these patterns are selected and controlled or even whether there ever exist sharp selection mechanisms. A related phenomenon is the spatial propagation of a pattern into a system which has been caused to become unstable against pattern-forming deformations. This phenomenon has some features in common with the propagation of sidebranching modes in dendritic solidification. In a class of one-dimensional models, the nonlinear system can be shown to select the propagating mode in which the leading edge of the pattern is just marginally stable. This stability principle, when applicable, predicts both the speed of propagation and the geometrical characteristics of the pattern which forms behind the moving front. A boundary-layer model for fully two or three dimensional solidification problems appears to exhibit similar mathematical behavior.

Modeling of multiphase flow with solidification and chemical reaction in materials processing

NASA Astrophysics Data System (ADS)

Wei, Jiuan

Understanding of multiphase flow and related heat transfer and chemical reactions are the keys to increase the productivity and efficiency in industrial processes. The objective of this thesis is to utilize the computational approaches to investigate the multiphase flow and its application in the materials processes, especially in the following two areas: directional solidification, and pyrolysis and synthesis. In this thesis, numerical simulations will be performed for crystal growth of several III-V and II-VI compounds. The effects of Prandtl and Grashof numbers on the axial temperature profile, the solidification interface shape, and melt flow are investigated. For the material with high Prandtl and Grashof numbers, temperature field and growth interface will be significantly influenced by melt flow, resulting in the complicated temperature distribution and curved interface shape, so it will encounter tremendous difficulty using a traditional Bridgman growth system. A new design is proposed to reduce the melt convection. The geometric configuration of top cold and bottom hot in the melt will dramatically reduce the melt convection. The new design has been employed to simulate the melt flow and heat transfer in crystal growth with large Prandtl and Grashof numbers and the design parameters have been adjusted. Over 90% of commercial solar cells are made from silicon and directional solidification system is the one of the most important method to produce multi-crystalline silicon ingots due to its tolerance to feedstock impurities and lower manufacturing cost. A numerical model is developed to simulate the silicon ingot directional solidification process. Temperature distribution and solidification interface location are presented. Heat transfer and solidification analysis are performed to determine the energy efficiency of the silicon production furnace. Possible improvements are identified. The silicon growth process is controlled by adjusting heating power and moving the side insulation layer upward. It is possible to produce high quality crystal with a good combination of heating and cooling. SiC based ceramic materials fabricated by polymer pyrolysis and synthesis becomes a promising candidate for nuclear applications. To obtain high uniformity of microstructure/concentration fuel without crack at high operating temperature, it is important to understand transport phenomena in material processing at different scale levels. In our prior work, a system level model based on reactive porous media theory was developed to account for the pyrolysis process in uranium-ceramic nuclear fabrication In this thesis, a particle level mesoscopic model based on the Smoothed Particle Hydrodynamics (SPH) is developed for modeling the synthesis of filler U3O8 particles and SiC matrix. The system-level model provides the thermal boundary conditions needed in the particle level simulation. The evolution of particle concentration and structure as well as composition of composite produced will be investigated. Since the process temperature and heat flux play the important roles in material quality and uniformity, the effects of heating rate at different directions, filler particle size and distribution on uniformity and microstructure of the final product are investigated. Uncertainty issue is also discussed. For the multiphase flow with directional solidification, a system level based on FVM is established. In this model, melt convection, temperature distribution, phase change and solidification interface can be investigated. For the multiphase flow with chemical reaction, a particle level model based on SPH method is developed to describe the pyrolysis and synthesis process of uranium-ceramic nuclear fuel. Due to its mesh-free nature, SPH can easily handle the problems with multi phases and components, large deformation, chemical reactions and even solidifications. A multi-scale meso-macroscopic approach, which combine a mesoscopic model based on SPH method and macroscopic model based on FVM, FEM and FDM, can be applied to even more complicated system. In the mesoscopic model by SPH method, some fundamental mesoscopic phenomena, such as the microstructure evolution, interface morphology represented by high resolution, particle entrapment in solidification can be studied. In the macroscopic model, the heat transfer, fluid flow, species transport can be modeled, and the simulation results provided the velocity, temperature and species boundary condition necessary for the mesoscopic model. This part falls into the region of future work. (Abstract shortened by UMI.)

Crystal Growth and Fluid Mechanics Problems in Directional Solidification

NASA Technical Reports Server (NTRS)

Tanveer, Saleh A.; Baker, Gregory R.; Foster, Michael R.

2001-01-01

Our work in directional solidification has been in the following areas: (1) Dynamics of dendrites including rigorous mathematical analysis of the resulting equations; (2) Examination of the near-structurally unstable features of the mathematically related Hele-Shaw dynamics; (3) Numerical studies of steady temperature distribution in a vertical Bridgman device; (4) Numerical study of transient effects in a vertical Bridgman device; (5) Asymptotic treatment of quasi-steady operation of a vertical Bridgman furnace for large Rayleigh numbers and small Biot number in 3D; and (6) Understanding of Mullins-Sererka transition in a Bridgman device with fluid dynamics is accounted for.

Directional solidification of a planar interface in the presence of a time-dependent electric current

NASA Technical Reports Server (NTRS)

Brush, L. N.; Coriell, S. R.; Mcfadden, G. B.

1990-01-01

Directional solidification of pure materials and binary alloys with a planar crystal-metal interface in the presence of a time-dependent electric current is considered. For a variety of time-dependent currents, the temperature fields and the interface velocity as functions of time are presented for indium antimonide and bismuth and for the binary alloys germanium-gallium and tin-bismuth. For the alloys, the solid composition is calculated as a function of position. Quantitative predictions are made of the effect of an electrical pulse on the solute distribution in the solidified material.

Benefits of rapid solidification processing of modified LaNi{sub 5} alloys by high pressure gas atomization for battery applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anderson, I.E.; Pecharsky, V.K.; Ting, J.

1997-12-31

A high pressure gas atomization approach to rapid solidification has been employed to investigate simplified processing of Sn modified LaNi{sub 5} powders that can be used for advanced Ni/metal hydride (Ni/MH) batteries. The current industrial practice involves casting large ingots followed by annealing and grinding and utilizes a complex and costly alloy design. This investigation is an attempt to produce powders for battery cathode fabrication that can be used in an as-atomized condition without annealing or grinding. Both Ar and He atomization gas were tried to investigate rapid solidification effects. Sn alloy additions were tested to promote subambient pressure absorption/desorptionmore » of hydrogen at ambient temperature. The resulting fine, spherical powders were subject to microstructural analysis, hydrogen gas cycling, and annealing experiments to evaluate suitability for Ni/MH battery applications. The results demonstrate that a brief anneal is required to homogenize the as-solidified microstructure of both Ar and He atomized powders and to achieve a suitable hydrogen absorption behavior. The Sn addition also appears to suppress cracking during hydrogen gas phase cycling in particles smaller than about 25 {micro}m. These results suggest that direct powder processing of a LaNi{sub 5{minus}x}Sn{sub x} alloy has potential application in rechargeable Ni/MH batteries.« less

Benefits of rapid solidification processing of modified LaNi{sub 5} alloys by high pressure gas atomization for battery applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anderson, I.E.; Pecharsky, V.K.; Ting, J.

1998-07-01

A high pressure gas atomization approach to rapid solidification has been employed to investigate simplified processing of Sn modified LaNi{sub 5} powders that can be used for advanced Ni/metal hydride (Ni/MH) batteries. The current industrial practice involves casting large ingots followed by annealing and grinding and utilizes a complex and costly alloy design. This investigation is an attempt to produce powders for battery cathode fabrication that can be used in an as-atomized condition without annealing or grinding. Both Ar and He atomization gas were tried to investigate rapid solidification effects. Sn alloy additions were tested to promote subambient pressure absorption/desorptionmore » of hydrogen at ambient temperature. The resulting fine, spherical powders were subject to microstructural analysis, hydrogen gas cycling, and annealing experiments to evaluate suitability for Ni/MH battery applications. The results demonstrate that a brief anneal is required to homogenize the as-solidified microstructure of both Ar and He atomized powders and to achieve a suitable hydrogen absorption behavior. The Sn addition also appears to suppress cracking during hydrogen gas phase cycling in particles smaller than about 25{micro}m. These results suggest that direct powder processing of a LaNi{sub 5{minus}x}Sn{sub x} alloy has potential application in rechargeable Ni/MH batteries.« less

Flight Planning for the International Space Station - Levitation Observation of Dendrite Evolution in Steel Ternary Alloy Rapid Solidification (LODESTARS)

NASA Technical Reports Server (NTRS)

Flemings, Merton C.; Matson, Douglas M.; Hyers, Robert W.; Rogers, Jan R.

2003-01-01

During rapid solidification, a molten sample is cooled below its equilibrium solidification temperature to form a metastable liquid. Once nucleation is initiated, growth of the solid phase proceeds and can be seen as a sudden rise in temperature. The heat of fusion is rejected ahead of the growing dendrites into the undercooled liquid in a process known as recalescence. Fe-Cr-Ni alloys may form several equilibrium phases and the hypoeutectic alloys, with compositions near the commercially important 316 stainless steel alloy, are observed to solidify by way of a two-step process known as double recalescence. During double recalescence, the first temperature rise is associated with formation of the metastable ferritic solid phase with subsequent conversion to the stable austenitic phase during the second temperature rise. Selection of which phase grows into the undercooled melt during primary solidification may be accomplished by choice of the appropriate nucleation trigger material or by control of the processing parameters during rapid solidification. Due to the highly reactive nature of the molten sample material and in order to avoid contamination of the undercooled melt, a containerless electromagnetic levitation (EML) processing technique is used. In ground-based EML, the same forces that support the weight of the sample against gravity also drive convection in the liquid sample. However, in microgravity, the force required to position the sample is greatly reduced, so convection may be controlled over a wide range of internal flows. Space Shuttle experiments have shown that the double recalescence behavior of Fe-Cr-Ni alloys changes between ground and space EML experiments. This program is aimed at understanding how melt convection influences phase selection and the evolution of rapid solidification microstructures.

Microstructural development during solidification of stainless steel alloys

NASA Astrophysics Data System (ADS)

Elmer, J. W.; Allen, S. M.; Eagar, T. W.

1989-10-01

The microstructures that develop during the solidification of stainless steel alloys are related to the solidification conditions and the specific alloy composition. The solidification conditions are determined by the processing method, i.e., casting, welding, or rapid solidification, and by parametric variations within each of these techniques. One variable that has been used to characterize the effects of different processing conditions is the cooling rate. This factor and the chemical composition of the alloy both influence (1) the primary mode of solidification, (2) solute redistribution and second-phase formation during solidification, and (3) the nucleation and growth behavior of the ferrite-to-austenite phase transformation during cooling. Consequently, the residual ferrite content and the microstructural morphology depend on the cooling rate and are governed by the solidification process. This paper investigates the influence of cooling rate on the microstructure of stainless steel alloys and describes the conditions that lead to the many microstructural morphologies that develop during solidification. Experiments were performed on a series of seven high-purity Fe-Ni-Cr alloys that spanned the line of twofold saturation along the 59 wt pct Fe isopleth of the ternary alloy system. High-speed electron-beam surface-glazing was used to melt and resolidify these alloys at scan speeds up to 5 m/s. The resulting cooling rates were shown to vary from 7°C/s to 7.5×106°C/s, and the resolidified melts were analyzed by optical metallographic methods. Five primary modes of solidification and 12 microstructural morphologies were characterized in the resolidified alloys, and these features appear to be a complete “set” of the possible microstructures for 300-series stainless steel alloys. The results of this study were used to create electron-beam scan speed vs composition diagrams, which can be used to predict the primary mode of solidification and the microstructural morphology for different processing conditions. Furthermore, changes in the primary solidification mode were observed in alloys that lie on the chromium-rich side of the line of twofold saturation when they are cooled at high rates. These changes were explained by the presence of metastable austenite, which grows epitaxially and can dominate the solidification microstructure throughout the resolidified zone at high cooling rates.

Liquid Phase Miscibility Gap Materials

NASA Technical Reports Server (NTRS)

Gelles, S. H.; Markworth, A. J.

1985-01-01

The manner in which the microstructural features of liquid-phase miscibility gap alloys develop was determined. This will allow control of the microstructures and the resultant properties of these alloys. The long-duration low gravity afforded by the shuttle will allow experiments supporting this research to be conducted with minimal interference from buoyancy effects and gravitationally driven convection currents. Ground base studies were conducted on Al-In, Cu-Pb, and Te-Tl alloys to determine the effect of cooling rate, composition, and interfacial energies on the phase separation and solidification processes that influence the development of microstructure in these alloys. Isothermal and directional cooling experiments and simulations are conducted. The ground based activities are used as a technological base from which flight experiments formulated and to which these flight experiments are compared.

Interaction of Multiple Particles with a Solidification Front: From Compacted Particle Layer to Particle Trapping.

PubMed

Saint-Michel, Brice; Georgelin, Marc; Deville, Sylvain; Pocheau, Alain

2017-06-13

The interaction of solidification fronts with objects such as particles, droplets, cells, or bubbles is a phenomenon with many natural and technological occurrences. For an object facing the front, it may yield various fates, from trapping to rejection, with large implications regarding the solidification pattern. However, whereas most situations involve multiple particles interacting with each other and the front, attention has focused almost exclusively on the interaction of a single, isolated object with the front. Here we address experimentally the interaction of multiple particles with a solidification front by performing solidification experiments of a monodisperse particle suspension in a Hele-Shaw cell with precise control of growth conditions and real-time visualization. We evidence the growth of a particle layer ahead of the front at a close-packing volume fraction, and we document its steady-state value at various solidification velocities. We then extend single-particle models to the situation of multiple particles by taking into account the additional force induced on an entering particle by viscous friction in the compacted particle layer. By a force balance model this provides an indirect measure of the repelling mean thermomolecular pressure over a particle entering the front. The presence of multiple particles is found to increase it following a reduction of the thickness of the thin liquid film that separates particles and front. We anticipate the findings reported here to provide a relevant basis to understand many complex solidification situations in geophysics, engineering, biology, or food engineering, where multiple objects interact with the front and control the resulting solidification patterns.

Behavior of ceramic particles at the solid-liquid metal interface in metal matrix composites

NASA Technical Reports Server (NTRS)

Stefanescu, D. M.; Dhindaw, B. K.; Kacar, S. A.; Moitra, A.

1988-01-01

Directional solidification results were obtained in order to investigate particle behavior at the solid-liquid interface in Al-2 pct Mg (cellular interface) and Al-6.1 pct Ni (eutectic interface) alloys. It is found that particles can be entrapped in the solid if adequate solidification rates and temperature gradients are used. Model results showed critical velocity values slightly higher than those obtained experimentally.

Low-gravity processing of superconducting compounds

NASA Technical Reports Server (NTRS)

Otto, G. H.

1976-01-01

Low gravity conditions can be sustained on earth for several seconds in an evacuated drop tube. Because radiation cooling is most effective at high temperatures, the refractive metals and alloys are prime candidates for free fall solidification. The results of initial experiments on droplet formation, droplet release, critical size and evaporation losses are given. The time required for free fall solidification of different size droplets is calculated. The materials studied were copper, niobium and vanadium, and a niobium-tin alloys. Improvements in purity, composition, homogeneity and stoichiometry are expected during free fall solidification of niobium based alloys which should become evident in an increase in the superconducting transition temperature.

On oscillatory microstructure during cellular growth of directionally solidified Sn–36at.%Ni peritectic alloy

PubMed Central

Peng, Peng; Li, Xinzhong; Li, Jiangong; Su, Yanqing; Guo, Jingjie

2016-01-01

An oscillatory microstructure has been observed during deep-cellular growth of directionally solidified Sn–36at.%Ni hyperperitectic alloy containing intermetallic compounds with narrow solubility range. This oscillatory microstructure with a dimension of tens of micrometers has been observed for the first time. The morphology of this wave-like oscillatory structure is similar to secondary dendrite arms, and can be observed only in some local positions of the sample. Through analysis such as successive sectioning of the sample, it can be concluded that this oscillatory microstructure is caused by oscillatory convection of the mushy zone during solidification. And the influence of convection on this oscillatory microstructure was characterized through comparison between experimental and calculations results on the wavelength. Besides, the change in morphology of this oscillatory microstructure has been proved to be caused by peritectic transformation during solidification. Furthermore, the melt concentration increases continuously during solidification of intermetallic compounds with narrow solubility range, which helps formation of this oscillatory microstructure. PMID:27066761

On oscillatory microstructure during cellular growth of directionally solidified Sn-36at.%Ni peritectic alloy.

PubMed

Peng, Peng; Li, Xinzhong; Li, Jiangong; Su, Yanqing; Guo, Jingjie

2016-04-12

An oscillatory microstructure has been observed during deep-cellular growth of directionally solidified Sn-36at.%Ni hyperperitectic alloy containing intermetallic compounds with narrow solubility range. This oscillatory microstructure with a dimension of tens of micrometers has been observed for the first time. The morphology of this wave-like oscillatory structure is similar to secondary dendrite arms, and can be observed only in some local positions of the sample. Through analysis such as successive sectioning of the sample, it can be concluded that this oscillatory microstructure is caused by oscillatory convection of the mushy zone during solidification. And the influence of convection on this oscillatory microstructure was characterized through comparison between experimental and calculations results on the wavelength. Besides, the change in morphology of this oscillatory microstructure has been proved to be caused by peritectic transformation during solidification. Furthermore, the melt concentration increases continuously during solidification of intermetallic compounds with narrow solubility range, which helps formation of this oscillatory microstructure.

The growth of metastable peritectic compounds

NASA Technical Reports Server (NTRS)

Pirich, R. G.

1984-01-01

The effects of directional solidification processing on the microstructural, compositional, and magnetic properties of high-melting-temperature, commercially important alloys which form from the liquid state via peritectic or eutectic type reactions were determined. Emphasis was placed on ferromagnetic compounds of the commercially important Co-Sm and Al-Mn systems. The primary dendrite spacing for eutectic Sm2Co17/Co scaled with negative square root of V and varied from approximately 50 microns for V 20 cm/h to hundreds of microns for V 10 cm/h. Since the crystal growth mechanism was dendritic rather than cooperative, the assoicated permanent magnet properties were rather poor. Magnetization as a function of sample orientation indicates that the easy axis of magnetization was primarily along the direction of solidification for the eutectic Sm2Co17/Co and peritectic SmCo5/Sm2Co17 compositions. For the Al-Mn case, magnetization and microstructural characterization suggest isotropic, polycrystalling growth for all solidification velocities studied.

Integrated System of Thermal/Dimensional Analysis for Quality Control of Metallic Melt and Ductile Iron Casting Solidification

NASA Astrophysics Data System (ADS)

Stan, Stelian; Chisamera, Mihai; Riposan, Iulian; Neacsu, Loredana; Cojocaru, Ana Maria; Stan, Iuliana

2018-03-01

The main objective of the present work is to introduce a specific experimental instrument and technique for simultaneously evaluating cooling curves and expansion or contraction of cast metals during solidification. Contraction/expansion analysis illustrates the solidification parameters progression, according to the molten cast iron characteristics, which are dependent on the melting procedure and applied metallurgical treatments, mold media rigidity and thermal behavior [heat transfer parameters]. The first part of the paper summarizes the performance of this two-mold device. Its function is illustrated by representative shrinkage tendency results in ductile cast iron as affected by mold rigidity (green sand and furan resin sand molds) and inoculant type (FeSi-based alloys), published in part previously. The second part of the paper illustrates an application of this equipment adapted for commercial foundry use. It conducts thermal analysis and volume change measurements in a single ceramic cup so that mold media as well as solidification conditions are constants, with cast iron quality as the variable. Experiments compared gray and ductile cast iron solidification patterns. Gray iron castings are characterized by higher undercooling at the beginning and at the end of solidification and lower graphitic expansion. Typically, ductile cast iron exhibits higher graphitic, initial expansion, conducive for shrinkage formation in soft molds.

Detachment of Tertiary Dendrite Arms during Controlled Directional Solidification in Aluminum - 7 wt Percent Silicon Alloys: Observations from Ground-based and Microgravity Processed Samples

NASA Technical Reports Server (NTRS)

Grugel, Richard N.; Erdman, Robert; Van Hoose, James R.; Tewari, Surendra; Poirier, David

2012-01-01

Electron Back Scattered Diffraction results from cross-sections of directionally solidified aluminum 7wt% silicon alloys unexpectedly revealed tertiary dendrite arms that were detached and mis-oriented from their parent arm. More surprisingly, the same phenomenon was observed in a sample similarly processed in the quiescent microgravity environment aboard the International Space Station (ISS) in support of the joint US-European MICAST investigation. The work presented here includes a brief introduction to MICAST and the directional solidification facilities, and their capabilities, available aboard the ISS. Results from the ground-based and microgravity processed samples are compared and possible mechanisms for the observed tertiary arm detachment are suggested.

Modeling of the Coupling of Microstructure and Macrosegregation in a Direct Chill Cast Al-Cu Billet

NASA Astrophysics Data System (ADS)

Heyvaert, Laurent; Bedel, Marie; Založnik, Miha; Combeau, Hervé

2017-10-01

The macroscopic multiphase flow and the growth of the solidification microstructures in the mushy zone of a direct chill (DC) casting are closely coupled. These couplings are the key to the understanding of the formation of the macrosegregation and of the non-uniform microstructure of the casting. In the present paper we use a multiphase and multiscale model to provide a fully coupled picture of the links between macrosegregation and microstructure in a DC cast billet. The model describes nucleation from inoculant particles and growth of dendritic and globular equiaxed crystal grains, fully coupled with macroscopic transport phenomena: fluid flow induced by natural convection and solidification shrinkage, heat, mass, and solute mass transport, motion of free-floating equiaxed grains, and of grain refiner particles. We compare our simulations to experiments on grain-refined and non-grain-refined industrial size billets from literature. We show that a transition between dendritic and globular grain morphology triggered by the grain refinement is the key to the explanation of the differences between the macrosegregation patterns in the two billets. We further show that the grain size and morphology are strongly affected by the macroscopic transport of free-floating equiaxed grains and of grain refiner particles.

Solidification of II-VI Compounds in a Rotating Magnetic Field

NASA Technical Reports Server (NTRS)

Gillies, D. C.; Volz, M. P.; Mazuruk, K.; Motakef, S.; Dudley, M.; Matyi, R.

1999-01-01

This project is aimed at using a rotating magnetic field (RMF) to control fluid flow and transport during directional solidification of elemental and compound melts. Microgravity experiments have demonstrated that small amounts of residual acceleration of less than a micro-g can initiate and prolong fluid flow, particularly when there is a static component of the field perpendicular to the liquid solid interface. Thus a true diffusion boundary layer is not formed, and it becomes difficult to verify theories of solidification or to achieve diffusion controlled solidification. The RMF superimposes a stirring effect on an electrically conducting liquid, and with appropriate field strengths and frequencies, controlled transport of material through a liquid column can be obtained. As diffusion conditions are precluded and complete mixing conditions prevail, the technique is appropriate for traveling solvent zone or float zone growth methods in which the overall composition of the liquid can be maintained throughout the growth experiment. Crystals grown by RMF techniques in microgravity in previous, unrelated missions have shown exceptional properties. The objective of the project is two-fold, namely (1) using numerical modeling to simulate the behavior of a solvent zone with applied thermal boundary conditions and demonstrate the effects of decreasing gravity levels, or an increasing applied RMF, or both, and (2) to grow elements and II-VI compounds from traveling solvent zones both with and without applied RMFs, and to determine objectively how well the modeling predicts solidification parameters. Numerical modeling has demonstrated that, in the growth of CdTe from a tellurium solution, a rotating magnetic field can advantageously modify the shape of the liquid solid interface such that the interface is convex as seen from the liquid. Under such circumstances, the defect structure is reduced as any defects which are formed tend to grow out and not propagate. The flow of liquid, however, is complex due to the competing flow induced by the rotating magnetic field and the buoyancy driven convection. When the acceleration forces are reduced to one thousandth of gravity, the flow pattern is much simplified and well controlled material transport through the solvent zone can be readily achieved. Triple axis diffractometry and x-ray synchrotron topography have demonstrated that there is no significant improvement in crystal quality for HgCdTe grown on earth from a tellurium solution when a rotating magnetic field is applied. However, modeling shows that the flow in microgravity with a rotating magnetic field would produce a superior product.

Two-dimensional time-resolved x-ray diffraction study of dual phase rapid solidification in steels

NASA Astrophysics Data System (ADS)

Yonemura, Mitsuharu; Osuki, Takahiro; Terasaki, Hidenori; Komizo, Yuichi; Sato, Masugu; Toyokawa, Hidenori; Nozaki, Akiko

2010-01-01

The high intensity heat source used for fusion welding creates steep thermal gradients of 100 °C/s from 1800 °C. Further, the influence of preferred orientation is important for the observation of a directional solidification that follows the dendrite growth along the ⟨100⟩ direction toward the moving heat source. In the present study, we observed the rapid solidification of weld metal at a time resolution of 0.01-0.1 s by a two-dimensional time-resolved x-ray diffraction (2DTRXRD) system for real welding. The diffraction rings were dynamically observed by 2DTRXRD with synchrotron energy of 18 keV while the arc passes over the irradiation area of the x-rays. The arc power output was 10 V-150 A, and the scan speed of the arc was 1.0 mm/s. The temperature rise in instruments was suppressed by a water-cooled copper plate under the specimen. Further, the temperature distribution of the weld metal was measured by a thermocouple and correlated with the diffraction patterns. Consequently, solidification and solid phase transformation of low carbon steels and stainless steels were observed during rapid cooling by 2DTRXRD. In the low carbon steel, the microstructure is formed in a two step process, (i) formation of crystallites and (ii) increase of crystallinity. In stainless steel, the irregular interface layer of δ/γ in the quenched metal after solidification is expected to show the easy movement of dendrites at a lower temperature. In carbide precipitation stainless steel, it is easy for NbC to grow on δ phase with a little undercooling. Further, a mistlike pattern, which differs from the halo pattern, in the fusion zone gave some indication of the possibilities to observe the nucleation and the early solidification by 2DTRXRD.

Localized melt-scan strategy for site specific control of grain size and primary dendrite arm spacing in electron beam additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Raghavan, Narendran; Simunovic, Srdjan; Dehoff, Ryan

In addition to design geometry, surface roughness, and solid-state phase transformation, solidification microstructure plays a crucial role in controlling the performance of additively manufactured components. Crystallographic texture, primary dendrite arm spacing (PDAS), and grain size are directly correlated to local solidification conditions. We have developed a new melt-scan strategy for inducing site specific, on-demand control of solidification microstructure. We were able to induce variations in grain size (30 μm–150 μm) and PDAS (4 μm - 10 μm) in Inconel 718 parts produced by the electron beam additive manufacturing system (Arcam®). A conventional raster melt-scan resulted in a grain size ofmore » about 600 μm. The observed variations in grain size with different melt-scan strategies are rationalized using a numerical thermal and solidification model which accounts for the transient curvature of the melt pool and associated thermal gradients and liquid-solid interface velocities. The refinement in grain size at high cooling rates (>104 K/s) is also attributed to the potential heterogeneous nucleation of grains ahead of the epitaxially growing solidification front. The variation in PDAS is rationalized using a coupled numerical-theoretical model as a function of local solidification conditions (thermal gradient and liquid-solid interface velocity) of the melt pool.« less

Sill and Laccolith growth by Inflation and Propagation--just not necessarily at the same time

NASA Astrophysics Data System (ADS)

Currier, R. M.; Marsh, B. D.

2013-12-01

Sill and laccolith growth is achieved by two key mechanisms, inflation (vertical growth) and propagation (radial growth). Of the myriad of models proposed for magmatic intrusion, all are variations on the same theme--some combination of inflation and propagation. Because of the inherent observational limitations in studying actual high-level crustal magma emplacement, there remains a poor consensus on any preferred model. To gain insight we have performed a series of simple experiments using layered gelatin as a viscoelastic crustal analog, and molten wax as magma analog. Wax is injected from the base of the gelatin mold, begins ascent as a dike, and is captured by the overlying, more rigid, layer of gelatin. The use of a solidifying magma analog separates these experiments from other gelatin-based studies. When water is used, a common choice for magma analog, the intrusion propagates in an extremely smooth manner. However, at the tip of any magma filled crack, where thickness is at a minimum, propagation and solidification are in fierce competition. The introduction of solidification reveals that emplacement actually occurs as a series of ensuing pulses--at times propagating and inflating concurrently, and at other times growth is achieved solely through propagation, or solely inflation. Unlike models without solidification, here no single combination of propagation and inflation accounts for growth, but rather, the different styles of emplacement reflect the relative competitiveness of propagation and solidification at that time and location. When propagation is fast relative to solidification, growth is smooth, and propagation and inflation occur simultaneously. When solidification dominates, propagation ceases, and growth by inflation becomes the chief emplacement mechanism. Nevertheless, regardless of the strong effect of solidification, building backpressure and the associated crack stresses can disrupt the chill zone at the sill edge, and bring on rapid propagation of magma in conjunction with overall sill deflation. Because the competitiveness of solidification increases with decreasing propagation velocity, and because propagation velocity of a growing magma body must necessarily decrease with time, these mechanisms are a fundamental feature of any magma body that grows for any extended period. Generally, larger flux rates correlate to larger radii and thinner sills. For classical laccolith formation, flux rate must be slow enough for solidification to curtail propagation at an early stage, effectively limiting radial growth and promoting further growth solely via inflation. The effects of this overall process occurs on multiple scales, and the history of the chilled margins can be clearly seen with a series of essentially ';chatter rinds' marking the staccato process of emplacement.

The materials processing research base of the Materials Processing Center

NASA Technical Reports Server (NTRS)

Latanision, R. M.

1986-01-01

An annual report of the research activities of the Materials Processing Center of the Massachusetts Institute of Technology is given. Research on dielectrophoresis in the microgravity environment, phase separation kinetics in immiscible liquids, transport properties of droplet clusters in gravity-free fields, probes and monitors for the study of solidification of molten semiconductors, fluid mechanics and mass transfer in melt crystal growth, and heat flow control and segregation in directional solidification are discussed.

Cellular instability in rapid directional solidification - Bifurcation theory

NASA Technical Reports Server (NTRS)

Braun, R. J.; Davis, S. H.

1992-01-01

Merchant and Davis performed a linear stability analysis on a model for the directional solidification of a dilute binary alloy valid for all speeds. The analysis revealed that nonequilibrium segregation effects modify the Mullins and Sekerka cellular mode, whereas attachment kinetics has no effect on these cells. In this paper, the nonlinear stability of the steady cellular mode is analyzed. A Landau equation is obtained that determines the amplitude of the cells. The Landau coefficient here depends on both nonequilibrium segregation effects and attachment kinetics. This equation gives the ranges of parameters for subcritical bifurcation (jump transition) or supercritical bifurcation (smooth transition) to cells.

Motion of Solid Grains During Magnetic Field-Assisted Directional Solidification

NASA Astrophysics Data System (ADS)

Wang, Jiang; Lin, Xin; Fautrelle, Yves; Nguyen-Thi, Henri; Ren, Zhongming

2018-06-01

In this paper, we report the visible evidence for thermoelectric magnetic forces (TEMFs) during magnetic field-assisted directional solidification, and their potential to control the motion of solid grains (dendrite fragments or equiaxed grains). These motions are observed by means of synchrotron X-ray radiography and compared with analytic calculations for a spherical particle's motion driven only by TEMFs, which confirms that the observed solid grain motions are the combined result of the TEMFs and gravity. We also carried out corresponding 3D numerical simulations to validate the calculations and further prove our conclusion that TEMF acts on the solid grain and affects its motion trajectory.

Shuttle Flight Experiment on USMP-4: In Situ Monitoring of Crystal Growth Using MEPHISTO

NASA Technical Reports Server (NTRS)

Abbaschian, Reza; deGroh, Henry C., III; Leonardi, E.; deVahlDavis, Graham; Coriell, Sam; Cambon, Gerard

2001-01-01

This reports on the MEPHISTO-4 experiment on the Space Shuttle Columbia, STS-87, November 19-December 5, 1997. Involved were NASA; the University of Florida at Gainesville; groups from France that developed and built the furnace; the National Institute of Standards and Technology; The University of New South Wales, Australia; and Purdue University. This was a solidification study in which three long rods of Bismuth- 1 at.% Tin were directionally solidified. The goals were to solidify in an environment free of natural convection; to determine the relationship among solidification growth velocity, growth mode, and temperature; and determine the diffusivity of Sn in Bi. The flight samples grew with a planar solid/liquid interface at velocities less than 3.4 gm/s, and cellular growth was present at velocities greater than 6.7 um/s; grain orientation influenced the planar to cellular transition. The temperature gradient in the liquid was 204 K/cm. The s/l interface was flat with slight concavity. Diffusion-dominated conditions were present during MEPHISTO-4. The Seebeck technique was used to determine the s/I interface temperature during growth, however, to date, analysis of the Seebeck results has not yielded a reliable measurement of the interface temperature. The partition coefficient for Bi alloyed with Sn was measured, k = 0.029.

Immiscible phase incorporation during directional solidification of hypermonotectics

NASA Technical Reports Server (NTRS)

Andrews, J. Barry; Merrick, Roger A.

1993-01-01

Solidification processes in immiscible samples were investigated by directly observing the events taking place at the solid-liquid interface during directional solidification. Visualization of these events was made possible through the use of a transparent metal analog system and a temperature gradient stage assembly fitted to an optical microscope. The immiscible transparent analog system utilized was the succinonitrile-glycerol system. This system has been shown to exhibit the same morphological transitions as observed in metallic alloys of monotectic composition. Both monotectic and hypermonotectic composition samples were directionally solidified in order to gain an improved understanding of the manner in which the excess hypermonotectic liquid is incorporated into the solidifying structure. The processing conditions utilized prevented sedimentation of the excess hypermonotectic liquid by directionally solidifying the samples in very thin (13 microns), horizontally oriented cells. High thermal gradient to growth rate ratios (G/R) were used in an effort to prevent constitutional supercooling and the subsequent formation of L(sub 2) droplets in advance of the solidification front during the growth of fibrous composite structures. Results demonstrated that hypermonotectic composites could be produced in samples up to two weight percent off of the monotectic composition by using a G/R ratio greater than or equal to 4.6 x 10(exp 4) C(s)/mm(sup 2) to avoid constitutional supercooling. For hypermonotectic samples processed with G/R ratios below 4.6 x 10(exp 4) C(s)/mm(sup 2), constitutional supercooling occurred and resulted in slight interfacial instability. For these samples, two methods of incorporation of the hypermonotectic liquid were observed and are reported. The correlation between the phase spacing, lambda, and the growth rate, R, was examined and was found to obey a relationship generally associated with a diffusion controlled coupled growth process. For samples with compositions ranging from the monotectic composition up to 2 percent off of the monotectic composition, data indicated that the square of the phase spacing (lambda) varied linearly with the inverse of the growth rate (R).

Microgravity

NASA Image and Video Library

2001-01-24

Typical metal sample that was processed by TEMPUS (Tiegelfreies Elektromagnetisches Prozessieren Unter Schwerelosigkeit), an electromagnetic levitation facility developed by German researchers and flown on the IML-2 and MSL-1 and 1R Spacelab missions. Electromagnetic levitation is used commonly in ground-based experiments to melt and then cool metallic melts below their freezing points without solidification occurring. Sample size is limited in ground-based experiments. Research with TEMPUS aboard Spacelab allowed scientists to study the viscosity, surface tension, and other properties of several metals and alloys while undercooled (i.e., cooled below their normal solidification points). The sample is about 1 cm (2/5 inch) in diameter.

Direct Observation of Pore Formation and Bubble Mobility during Controlled Melting and Resolidification in Microgravity

NASA Technical Reports Server (NTRS)

Grugel, Richard N.; Anilkumar, A. V.; Lee, C. P.

2004-01-01

Detailed studies on the controlled melting and subsequent re-solidification of succinonitrile were conducted in the microgravity environment aboard the International Space Station (ISS) using the PFMI apparatus (Pore Formation and Mobility Investigation) located in the ISS glovebox facility (GBX). Samples were initially prepared on ground by filling glass tubes, 1 cm ID and approximately 30 cm in length, with pure succinonitrile (SCN) under 450 millibar of nitrogen. During Space processing, experimental parameters like temperature gradient and translation speed, for melting and solidification, were remotely monitored and controlled from the ground Telescience Center (TSC) at the Marshall Space Flight Center. Real time visualization during controlled melting revealed bubbles of different sizes initiating at the solid/liquid interface, and traveling up the temperature gradient ahead of them. Subsequent controlled re-solidification of the SCN revealed the details of porosity formation and evolution. A preliminary analysis of the melt back and re- solidification and its implications to future microgravity materials processing is presented and discussed.

BUNDLE: A Novel Furnace for Performing Controlled Directional Solidification Experiments in a Microgravity Environment

NASA Technical Reports Server (NTRS)

Carrasquillo, Edgar J.; Griffin, Mark R.; Hammond, Monica S.; Johnson, Martin L.; Grugel, R. N.

2000-01-01

NASA Marshall Space Flight Center has developed a novel directional solidification furnace prototype for processing metals and alloys experiments in a microgravity environment. The BUNDLE (Bridgman Unidirectional Dendrite in Liquid Experiment) furnace is intended to accommodate the science requirements of Flight Definition Principle Investigators studying cellular/dendritic growth in aluminum and lead alloys at processing temperatures up to 1200 C. The furnace implements a number of innovative features to achieve high thermal gradients and quench rates in a low-power, light-weight design. These include a pyrolytic boron nitride/graphite composite heating element surrounded by layers of self-supporting refractory metal shielding, and a graphite fiber enhanced cold zone allowing high levels of heat extraction from the sample crucible. Novel to the BUNDLE design is an in-situ helium gas quench capability that ensures rapid freezing of the solidifying region (mushy zone) of the metal sample within the furnace without sample disturbance prior to quenching; this is a stringent requirement for subsequent analysis and understanding of microstructural development. The experiment hardware concept features multiple furnaces that may be "bundled" together so many samples, currently up to eight, can be processed at one time. The design of BUNDLE is flexible enough to be implemented on the Shuttle and Space Station in a number of locations (SpaceHab, Express Rack, MPESS, ISPR, etc). BUNDLE prototype furnaces have directionally solidified and quenched 1cm diameter lead - 5.8 weight percent antimony and aluminum - 4 weight percent copper alloys. Quenching of the mushy zone, as recorded by in-situ thermocouples, occurred on the order of 0.5 seconds or less, a rate within the PI's requirements. Subsequent metallographic examination revealed the solidified microstructure to be, as expected, unidirectional. Both the dendrite tips and the eutectic reaction were planar in nature indicating uniform axial heat flow. Delineation between the growing dendrites and eutectic structure with the "quenched-in" liquid was sharp, attesting to the efficacy of the helium quench. BUNDLE's conception, development, capability, and adaptability are presented (in view of Flight PI's needs and science requirements) through viewgraphs depicting actual hardware, generated thermal analysis, and micrographs prepared from BUNDLE processed, flight-like samples.

BUNDLE - A Novel Furnace for Performing Controlled Directional Solidification Experiments in a Microgravity Environment

NASA Technical Reports Server (NTRS)

Carrasquillo, Edgar J.; Griffin, Mark R.; Hammond, Monica S.; Johnson, Martin L.; Grugel, R. N.

2001-01-01

NASA Marshall Space Flight Center has developed a novel directional solidification furnace prototype for processing metals and alloys experiments in a microgravity environment. The BUNDLE (Bridgman Unidirectional Dendrite in Liquid Experiment) furnace is intended to accommodate the science requirements of Flight Definition Principle Investigators studying cellular/dendritic growth in aluminum and lead alloys at processing temperatures up to 1200 C. The furnace implements a number of innovative features to achieve high thermal gradients and quench rates in a low-power, light-weight design. These include a pyrolytic boron nitride/graphite composite heating element surrounded by layers of self-supporting refractory metal shielding, and a graphite fiber enhanced cold zone allowing high levels of heat extraction from the sample crucible. Novel to the BUNDLE design is an in-situ helium gas quench capability that ensures rapid freezing of the solidifying region (mushy zone) of the metal sample within the furnace without sample disturbance prior to quenching; this is a stringent requirement for subsequent analysis and understanding of microstructural development. The experiment hardware concept features multiple furnaces that may be "bundled" together so many samples, currently up to eight, can be processed at one time. The design of BUNDLE is flexible enough to be implemented on the Shuttle and Space Station in a number of locations (SpaceHab, Express Rack, MPESS, ISPR, etc). BUNDLE prototype furnaces have directionally solidified and quenched 1cm diameter lead - 5.8 weight percent antimony and aluminum - 4 weight percent copper alloys. Quenching of the mushy zone, as recorded by in-situ thermocouples, occurred on the order of 0.5 seconds or less, a rate within the PI's requirements. Subsequent metallographic examination revealed the solidified microstructure to be, as expected, unidirectional. Both the dendrite tips and the eutectic reaction were planar in nature indicating uniform axial heat flow. Delineation between the growing dendrites and eutectic structure with the "quenched-in" liquid was sharp, attesting to the efficacy of the helium quench. BUNDLE's conception, development, capability, and adaptability are presented (in view of Flight PI's needs and science requirements) through viewgraphs depicting actual hardware, generated thermal analysis, and micrographs prepared from BUNDLE processed, flight-like samples.

Transverse tensile and stress rupture properties of gamma/gamma prime-delta directionally solidified eutectic

NASA Technical Reports Server (NTRS)

Gray, H. H.

1976-01-01

Tensile and stress rupture properties were determined primarily at 760 C for specimens oriented at various angles (0 deg, 10 deg, 45 deg, and 90 deg) from the solidification direction of bars and/or slabs of the Ni-20Cb-6Cr-2.5A (gamma/gamma prime-delta) eutectic. Threaded-head specimens yielded longer rupture lives with significantly less scatter than did tapered-head specimens. Miniature specimens are suitable for determining traverse tensile and rupture properties of 1.2 centimeter diameter bar stock. The 300 hour rupture stress at 760 C for specimens oriented at 10 deg from the solidification direction was reduced from 740 to 460 MPa, and to 230 MPa for material oriented at either 45 deg or 90 deg.

Thermosolutal convection during directional solidification. II - Flow transitions

NASA Technical Reports Server (NTRS)

Mcfadden, G. B.; Coriell, S. R.

1987-01-01

The influence of thermosolutal convection on solute segregation in crystals grown by vertical directional solidification of binary metallic alloys or semiconductors is studied. Finite differences are used in a two-dimensional time-dependent model which assumes a planar crystal-melt interface to obtain numerical results. It is assumed that the configuration is periodic in the horizontal direction. Consideration is given to the possibility of multiple flow states sharing the same period. The results are represented in bifurcation diagrams of the nonlinear states associated with the critical points of linear theory. Variations of the solutal Rayleigh number can lead to the occurrence of multiple steady states, time-periodic states, and quasi-periodic states. This case is compared to that of thermosolutal convection with linear vertical gradients and stress-free boundaries.

Thermal analysis of HGFQ using FIDAP(trademark): Solidification front motion

NASA Technical Reports Server (NTRS)

Woodbury, Keith A.

1996-01-01

The High Gradient Furnace with Quench (HGFQ) is being designed by NASA/MSFC for flight on the International Space Station. The furnace is being designed specifically for solidification experiments in metal and metallic alloy systems. The HGFQ Product development Team (PDT) has been active since January 1994 and their effort is now in early Phase B. Thermal models have been developed both by NASA and Sverdrup (support contractor) to assist in the HGFQ design effort. Both these models use SINDA as a solution engine, but the NASA model was developed using PATRAN and includes more detail than the Sverdrup model. These models have been used to guide design decisions and have been validated through experimentation on a prototypical 'Breadboard' furnace at MSFC. One facet of the furnace operation of interest to the designers is the sensitivity of the solidification interface location to changes in the furnace setpoint. Specifically of interest is the motion (position and velocity) of the solidification front due to a small perturbation in the furnace temperature. FIDAP(TM) is a commercially available finite element program for analysis of heat transfer and fluid flow processes. Its strength is in solution of the Navier-Stokes equations for incompressible flow, but among its capabilities is the analysis of transient processes involving radiation and solidification. The models presently available from NASA and Sverdrup are steady-state models and are incapable of computing the motion of the solidification front. The objective of this investigation is to use FIDAP(TM) to compute the motion of the solidification interface due to a perturbation in the furnace setpoint.

Fundamental Studies of Solidification in Microgravity Using Real-Time X-Ray Microscopy

NASA Technical Reports Server (NTRS)

Curreri, Peter A.; Kaukler, William; Sen, Subhayu; Bhat, Biliyar N.

1999-01-01

This research applies a state of the art X-ray Transmission Microscope, XTM, to image (with resolutions up to 3 micrometers) the solidification of metallic or semiconductor alloys in real-time. We have successfully imaged in real-time: interfacial morphologies, phase growth, coalescence, incorporation of phases into the growing interface, and the solute boundary layer in the liquid at the solid-liquid interface. We have also measured true local growth rates and can evaluate segregation structures in the solid; a form of in-situ metallography. During this study, the growth of secondary phase fibers and lamellae from eutectic and monotectic alloys have been imaged during solidification, in real-time, for the first time in bulk metal alloys. Current high resolution X-ray sources and high contrast X-ray detectors have advanced to allow systematic study of solidification dynamics and the resulting microstructure. We have employed a state-of-the-art sub-micron source with acceleration voltages of 10-100 kV to image solidification of metals. One useful strength of the XTM stems from the manner an image is formed. The radiographic image is a shadow formed by x-ray photons that are not absorbed as they pass through the specimen. Composition gradients within the specimen cause variations in absorption of the flux such that the final image represents a spatial integral of composition (or thickness). The ability to image these features in real-time enables more fundamental and detailed understanding of solidification dynamics than has previously been possible. Hence, application of this technique towards microgravity experiments will allow rigorous testing of critical solidification models.

Metastable phase formation in undercooled Fe-Co melts under terrestrial and parabolic flight conditions

NASA Astrophysics Data System (ADS)

Hermann, R.; Löser, W.; Lindenkreuz, H. G.; Yang-Bitterlich, W.; Mickel, Ch.; Diefenbach, A.; Schneider, S.; Dreier, W.

2007-12-01

Soft magnetic Fe-Co alloys display primary fcc phase solidification for>19,5 at% Co in conventional near-equilibrium solidification processes. Undercooled Fe-Co melt drops within the composition range of 30 to 50 at% Co have been investigated with the electromagnetic levitation technique. The solidification kinetics was measured in situ using a high-resolution Siphotodiode. Melt drops were undercooled up to 263 K below the liquidus temperature and subsequently quenched onto a chill substrate in order to characterize the solidification sequence and microstructure. The transition from stable fcc phase to metastable bcc primary phase solidification has been observed after reaching a critical undercooling level. The critical undercooling increases with rising Co content. The growth velocity drops obviously after transition to metastable bcc phase formation. Parabolic flight experiments were performed in order to study the phase selection under reduced gravity conditions. Under microgravity conditions, a much smaller critical undercooling and an increased life time of the metastable bcc phase were obtained. This result was validated with TEM investigations. The appearance of Fe-O particles gives an indirect hint for an intermediate fcc phase formation from the metastable bcc phase at elevated temperature.

Preferred growth orientation and microsegregation behaviors of eutectic in a nickel-based single-crystal superalloy

PubMed Central

Ma, Dexin; Bührig-Polaczek, Andreas

2015-01-01

A nickel-based single-crystal superalloy was employed to investigate the preferred growth orientation behavior of the (γ + γ′) eutectic and the effect of these orientations on the segregation behavior. A novel solidification model for the eutectic island was proposed. At the beginning of the eutectic island’s crystallization, the core directly formed from the liquid by the eutectic reaction, and then preferably grew along [100] direction. The crystallization of the eutectic along [110] always lagged behind that in [100] direction. The eutectic growth in [100] direction terminated on impinging the edge of the dendrites or another eutectic island. The end of the eutectic island’s solidification terminates due to the encroachment of the eutectic liquid/solid interface at the dendrites or another eutectic island in [110] direction. The distribution of the alloying elements depended on the crystalline axis. The degree of the alloying elements’ segregation was lower along [100] than [110] direction with increasing distance from the eutectic island’s center. PMID:27877773

Morphological Evolution of Directional Solidification Interfaces in Microgravity: An Analysis of Model Experiments Performed on the International Space Station

NASA Technical Reports Server (NTRS)

Strutzenberg, Louise L.; Grugel, R. N.; Trivedi, R. K.

2005-01-01

A series of experiments performed using the Pore Formation and Mobility Investigation (PFMI) apparatus within the glovebox facility (GBX) on board the International Space Station (ISS) has provided video images of the morphological evolution of a three-dimensional interface in a diffusion controlled regime. The experimental samples were prepared on ground by filling glass tubes, 1 cm ID and approximately 30 cm in length, with "alloys" of succinonitrile (SCN) and water in an atmosphere of nitrogen at 450 millibar pressure. The compositions of the samples processed and analyzed are 0.25,0.5 and 1.0 wt% water. Experimental processing parameters of temperature gradient and translation speed, as well as camera settings, were remotely monitored and manipulated from the ground Telescience Center (TSC) at the Marshall !3pace Flight Center. During the experiments, the sample was first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. Following the melt back, the interface was allowed to stabilize before translation is initiated. The temperatures in the sample were monitored by six in situ thermocouples and the position is monitored by an optical linear encoder. For the experiments performed and analyzed, the gradients ranged from 2.5 - 3.3 K/mm and the initial pulling velocities ranged from 0.7 micron per second to 1 micron per second with subsequent transition velocities of up to 100 microns per second. The data provided by the PFMI for analysis includes near-real-time (NRT) video captured on the ground during the experiment runs, ISS Video Tape Recorder (VTR) data dumped from the VTR at the end of the experiment run and recorded on the ground, telemetry data including temperature and position measurements, and limited flight HI-8 tapes in 2 camera views of experiment runs for which tapes have been returned to the investigators from ISS. Because of limited down mass from the ISS, the majority of the initial analysis has been performed using the NRT and VTR video data but will be supplemented with the HI-8 video as it becomes available. hardware and procedures required to prepare samples for correlation to flight samples is described. Using this ground-based system, a series of experiments have been performed for direct comparison with the flight data. The results of these comparisons as well as implications to future microgravity experiments are presented and discussed. A ground-based thin-sample directional solidification system as well as all associated

Convective and morphological instabilities during crystal growth: Effect of gravity modulation

NASA Technical Reports Server (NTRS)

Coreill, S. R.; Murray, B. T.; Mcfadden, G. B.; Wheeler, A. A.; Saunders, B. V.

1992-01-01

During directional solidification of a binary alloy at constant velocity in the vertical direction, morphological and convective instabilities may occur due to the temperature and solute gradients associated with the solidification process. The effect of time-periodic modulation (vibration) is studied by considering a vertical gravitational acceleration which is sinusoidal in time. The conditions for the onset of solutal convection are calculated numerically, employing two distinct computational procedures based on Floquet theory. In general, a stable state can be destabilized by modulation and an unstable state can be stabilized. In the limit of high frequency modulation, the method of averaging and multiple-scale asymptotic analysis can be used to simplify the calculations.

Self Assembled Structures by Directional Solidification of Eutectics

NASA Technical Reports Server (NTRS)

Dynys, Frederick W.; Sayir, Ali

2004-01-01

Interest in ordered porous structures has grown because of there unique properties such as photonic bandgaps, high backing packing density and high surface to volume ratio. Inspired by nature, biometric strategies using self assembled organic molecules dominate the development of hierarchical inorganic structures. Directional solidification of eutectics (DSE) also exhibit self assembly characteristics to form hierarchical metallic and inorganic structures. Crystallization of diphasic materials by DSE can produce two dimensional ordered structures consisting of rods or lamella. By selective removal of phases, DSE is capable to fabricate ordered pore arrays or ordered pin arrays. Criteria and limitations to fabricate hierarchical structures will be presented. Porous structures in silicon base alloys and ceramic systems will be reported.

Evidence for an early wet Moon from experimental crystallization of the lunar magma ocean

NASA Astrophysics Data System (ADS)

Lin, Yanhao; Tronche, Elodie J.; Steenstra, Edgar S.; van Westrenen, Wim

2017-01-01

The Moon is thought to have been covered initially by a deep magma ocean, its gradual solidification leading to the formation of the plagioclase-rich highland crust. We performed a high-pressure, high-temperature experimental study of lunar mineralogical and geochemical evolution during magma ocean solidification that yields constraints on the presence of water in the earliest lunar interior. In the experiments, a deep layer containing both olivine and pyroxene is formed in the first ~50% of crystallization, β-quartz forms towards the end of crystallization, and the last per cent of magma remaining is extremely iron rich. In dry experiments, plagioclase appears after 68 vol.% solidification and yields a floatation crust with a thickness of ~68 km, far above the observed average of 34-43 km based on lunar gravity. The volume of plagioclase formed during crystallization is significantly less in water-bearing experiments. Using the relationship between magma water content and the resulting crustal thickness in the experiments, and considering uncertainties in initial lunar magma ocean depth, we estimate that the Moon may have contained at least 270 to 1,650 ppm water at the time of magma ocean crystallization, suggesting the Earth-Moon system was water-rich from the start.

Understanding Superfine Graphite Iron Solidification Through Interrupted Solidification Experiments

NASA Astrophysics Data System (ADS)

Alonso, G.; Stefanescu, D. M.; Larrañaga, P.; De la Fuente, E.; Aguado, E.; Suarez, R.

The tensile strength of near-eutectic gray iron can be increased from 230-300 to 300-345MPa, without a significant increase in hardness, through 0.3-0.4%Ti addition to low sulfur (<0.01%S) iron. This is due to the combination of higher primary austenite/eutectic ratio and the precipitation of superfine-interdendritic-graphite (SIG), characterized by a fine (10-20μm) and highly branched fibrous structure.

Elimination of Hot Tears in Steel Castings by Means of Solidification Pattern Optimization

NASA Astrophysics Data System (ADS)

Kotas, Petr; Tutum, Cem Celal; Thorborg, Jesper; Hattel, Jesper Henri

2012-06-01

A methodology of how to exploit the Niyama criterion for the elimination of various defects such as centerline porosity, macrosegregation, and hot tearing in steel castings is presented. The tendency of forming centerline porosity is governed by the temperature distribution close to the end of the solidification interval, specifically by thermal gradients and cooling rates. The physics behind macrosegregation and hot tears indicate that these two defects also are dependent heavily on thermal gradients and pressure drop in the mushy zone. The objective of this work is to show that by optimizing the solidification pattern, i.e., establishing directional and progressive solidification with the help of the Niyama criterion, macrosegregation and hot tearing issues can be both minimized or eliminated entirely. An original casting layout was simulated using a transient three-dimensional (3-D) thermal fluid model incorporated in a commercial simulation software package to determine potential flaws and inadequacies. Based on the initial casting process assessment, multiobjective optimization of the solidification pattern of the considered steel part followed. That is, the multiobjective optimization problem of choosing the proper riser and chill designs has been investigated using genetic algorithms while simultaneously considering their impact on centerline porosity, the macrosegregation pattern, and primarily on hot tear formation.

A Simplified Three-Phase Model of Equiaxed Solidification for the Prediction of Microstructure and Macrosegregation in Castings

NASA Astrophysics Data System (ADS)

Tveito, Knut Omdal; Pakanati, Akash; M'Hamdi, Mohammed; Combeau, Hervé; Založnik, Miha

2018-04-01

Macrosegregation is a result of the interplay of various transport mechanisms, including natural convection, solidification shrinkage, and grain motion. Experimental observations also indicate the impact of grain morphology, ranging from dendritic to globular, on macrosegregation formation. To avoid the complexity arising due to modeling of an equiaxed dendritic grain, we present the development of a simplified three-phase, multiscale equiaxed dendritic solidification model based on the volume-averaging method, which accounts for the above-mentioned transport phenomena. The validity of the model is assessed by comparing it with the full three-phase model without simplifications. It is then applied to qualitatively analyze the impact of grain morphology on macrosegregation formation in an industrial scale direct chill cast aluminum alloy ingot.

Research on metal solidification in zero-g state

NASA Technical Reports Server (NTRS)

Papazian, J. M.; Larson, D. J., Jr.

1975-01-01

The containerless solidification of several pure metals and metallic alloys was studied in a low gravity environment. The tests were performed in the MSFC 4.2 s drop tower using a rapid wire melting apparatus designed and built for this purpose. Pure iron and nickel, and alloys of iron-nickel, iron-carbon, nickel-aluminum and tungsten-rhenium were all melted and solidified at a gravity level of approximately 100.000/-4 g. Interpretation of the results has led to an appreciation of the factors controlling the successful execution of this drop test experiment and to a delineation of the limits of applicability of the apparatus. Preliminary metallurgical evaluations are presented of the overall shapes, lattice parameters, surface microstructure,, cross-sectional microstructures, solidification and transformation sequences, evaporative segregation, and localized solute redistribution observed in the low-gravity specimens. The effects of low gravity on metallic solidification are discussed with particular emphasis on observations of spontaneous undercooling and evaporative segregation in uncontained melts.

Modeling the interaction of biological cells with a solidifying interface

NASA Astrophysics Data System (ADS)

Chang, Anthony; Dantzig, Jonathan A.; Darr, Brian T.; Hubel, Allison

2007-10-01

In this article, we develop a modified level set method for modeling the interaction of particles with a solidifying interface. The dynamic computation of the van der Waals and drag forces between the particles and the solidification front leads to a problem of multiple length scales, which we resolve using adaptive grid techniques. We present a variety of example problems to demonstrate the accuracy and utility of the method. We also use the model to interpret experimental results obtained using directional solidification in a cryomicroscope.

Modeling Macrosegregation in Directionally Solidified Aluminum Alloys under Gravitational and Microgravitational Conditions.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lauer, Mark A.; Poirier, David R.; Erdmann, Robert G.

2014-09-01

This report covers the modeling of seven directionally solidified samples, five under normal gravitational conditions and two in microgravity. A model is presented to predict macrosegregation during the melting phases of samples solidified under microgravitational conditions. The results of this model are compared against two samples processed in microgravity and good agreement is found. A second model is presented that captures thermosolutal convection during directional solidification. Results for this model are compared across several experiments and quantitative comparisons are made between the model and the experimentally obtained radial macrosegregation profiles with good agreement being found. Changes in cross section weremore » present in some samples and micrographs of these are qualitatively compared with the results of the simulations. It is found that macrosegregation patterns can be affected by changing the mold material.« less

Positive Ion Induced Solidification of He4

NASA Astrophysics Data System (ADS)

Moroshkin, P.; Lebedev, V.; Weis, A.

2009-03-01

We have observed bulk solidification of He4 induced by nucleation on positive alkali ions in pressurized superfluid helium. The ions are extracted into the liquid from alkali-doped solid He by a static electric field. The experiments prove the existence of charged particles in a solid structure composed of doped He that was recently shown to coexist with superfluid helium below the He solidification pressure. This supports our earlier suggestion that the Coulomb interaction of positive ions surrounded by a solid He shell (snowballs) and electrons trapped in spherical cavities (electron bubbles), together with surface tension, is responsible for the stability of that structure against melting. We have determined the density of charges in the sample by two independent methods.

Orientation Dependence of Columnar Dendritic Growth with Sidebranching Behaviors in Directional Solidification: Insights from Phase-Field Simulations

NASA Astrophysics Data System (ADS)

Xing, Hui; Dong, Xianglei; Wang, Jianyuan; Jin, Kexin

2018-04-01

In this study, a thin-interface phase-field model was employed to study the orientation dependence of the columnar dendritic growth with sidebranching behaviors in directional solidification. It was found that the dimensionless tip undercooling increases with the increase of misorientation angle for three pulling velocities. The primary spacing is found to be a function of misorientation angle, and the dimensionless primary spacing with respect to the misorientation angle follows the orientation correction given by Gandin and Rappaz (Acta. Metall. 42:2233-2246, 1994). For the analysis of the dendritic tip, the two-dimensional (2-D) form of the nonaxisymmetric needle crystal was used to determine the radius of the tilted columnar dendrite. Based on the definitions of open side and constrained side of the dendrite, the analysis of the width active sidebranches and the dendritic area in 2-D with respect to the distance from the dendritic tip was carried out to investigate the asymmetrical dendrite envelop and sidebranching behaviors on the two sides in directional solidification. The obtained prefactor and exponent with respect to misorientation angle are discussed, showing that the sidebranching behaviors of a tilted columnar dendritic array obey a similar power-law relationship with that of a free dendritic growth.

Segregation and microstructure evolution in chill cast and directionally solidified Ni-Mn-Sn metamagnetic shape memory alloys

NASA Astrophysics Data System (ADS)

Czaja, P.; Wierzbicka-Miernik, A.; Rogal, Ł.

2018-06-01

A multiphase solidification behaviour is confirmed for a range of Ni-rich and Ni-deficient Ni-Mn-Sn induction cast and directionally solidified (Bridgman) alloys. The composition variation is primarily linked to the changing Mn/Sn ratio, whereas the content of Ni remains largely stable. The partitioning coefficients for the Ni50Mn37Sn13 and Ni46Mn41.5Sn12.5 Bridgman alloys were obtained according to the Scheil equation based on the composition distribution along the longitudinal cross section of the ingots. Homogenization heat treatment performed for 72 h at 1220 K turned out sufficient for ensuring chemical uniformity on the macro- and microscale. It is owed to a limited segregation length scale due to slow cooling rates adopted for the directional solidification process.

{1 1 1} facet growth laws and grain competition during silicon crystallization

NASA Astrophysics Data System (ADS)

Stamelou, V.; Tsoutsouva, M. G.; Riberi-Béridot, T.; Reinhart, G.; Regula, G.; Baruchel, J.; Mangelinck-Noël, N.

2017-12-01

Directional solidification from mono-crystalline Si seeds having different orientations along the growth direction is studied. Due to the frequent twinning phenomenon, new grains soon nucleate during growth. The grain competition is then characterized in situ by imaging the dynamic evolution of the grain boundaries and of the corresponding grain boundary grooves that are formed at the solid-liquid interface. To perform this study, an experimental investigation based on Bridgman solidification technique coupled with in situ X-ray imaging is conducted in an original device: GaTSBI (Growth at high Temperature observed by X-ray Synchrotron Beam Imaging). Imaging characterisation techniques using X-ray synchrotron radiation at ESRF (European Synchrotron Radiation Facility, Grenoble, France) are applied during the solidification to study the growth dynamics. Facetted/facetted grain boundary grooves only are studied due to their importance in the grain competition because of their implication in the twinning mechanism. The maximum undercooling inside the groove is calculated from the groove depth knowing the local temperature gradient. Additionally, thanks to dynamic X-ray images, the global solid-liquid interface growth rate and the normal growth rate of the {1 1 1} facets existing at the grooves and at the edges are measured. From these measurements, experimental growth laws that correlate the normal velocity of the {1 1 1} facets with the maximum undercooling of the groove are extracted and compared to existing theoretical models. Finally, the experimental laws found for the contribution to the undercooling of the {1 1 1} facets are in good agreement with the theoretical model implying nucleation and growth eased by the presence of dislocations. Moreover, it is shown that, for the same growth parameters, the undercooling at the level of the facets (always lower than 1 K) is higher at the edges so that there is a higher probability of twin nucleation at the edges which is in agreement with the grain structure development characterised in the present experiments as well as in the literature.

Microstructural investigation of D2 tool steel during rapid solidification

NASA Astrophysics Data System (ADS)

Delshad Khatibi, Pooya

Solidification is considered as a key processing step in developing the microstructure of most metallic materials. It is, therefore, important that the solidification process can be designed and controlled in such a way so as to obtain the desirable properties in the final product. Rapid solidification refers to the system's high undercooling and high cooling rate, which can yield a microstructure with unique chemical composition and mechanical properties. An area of interest in rapid solidification application is high-chromium, high-carbon tool steels which experience considerable segregation of alloying elements during their solidification in a casting process. In this dissertation, the effect of rapid solidification (undercooling and cooling rate) of D2 tool steel on the microstructure and carbide precipitation during annealing was explored. A methodology is described to estimate the eutectic and primary phase undercooling of solidifying droplets. The estimate of primary phase undercooling was confirmed using an online measurement device that measured the radiation energy of the droplets. The results showed that with increasing primary phase and eutectic undercooling and higher cooling rate, the amount of supersaturation of alloying element in metastable retained austenite phase also increases. In the case of powders, the optimum hardness after heat treatment is achieved at different temperatures for constant periods of time. Higher supersaturation of austenite results in obtaining secondary hardness at higher annealing temperature. D2 steel ingots generated using spray deposition have high eutectic undercooling and, as a result, high supersaturation of alloying elements. This can yield near net shape D2 tool steel components with good mechanical properties (specifically hardness). The data developed in this work would assist in better understanding and development of near net shape D2 steel spray deposit products with good mechanical properties.

PREFACE: Third International Conference on Advances in Solidification Processes (ICASP - 3)

NASA Astrophysics Data System (ADS)

Zimmermann, Gerhard; Ratke, Lorenz

2012-01-01

The 3rd International Conference on Advances in Solidification Processes was held in the Rolduc Abbey in the Netherlands a few kilometres away from Aachen. Around 200 scientists from 24 countries come in for the four day meeting. They found a stimulating but also relaxing environment and atmosphere, with beautiful weather and the medieval abbey inviting for walks, discussions, sitting outside and drinking a beer or wine. The contributions given at the conference reflected recent advances in various topics of solidification processes, ranging from fundamental aspects to applied casting technologies. In 20 oral sessions and a large poster session innovative results of segregation phenomena, microstructure evolution, nucleation and growth, phase formation, polyphase solidification, rapid solidification and welding, casting technology, thermophysics of molten alloys, solidification with forced melt flow and growth of single crystals and superalloys together with innovative diagnostic techniques were presented. Thereby, findings from experiments as well as from numerical modeling on different lengths scales were jointly discussed and contribute to new insight in solidification behaviour. The papers presented in this open access proceedings cover about half the oral and poster presentations given. They were carefully reviewed as in classical peer reviewed journals by two independent referees and most of them were revised and thus improved according to the reviewers comments. We think that this collection of papers presented at ICASP-3 gives an impression of the excellent contributions made. The papers embrace both the basic and applied aspects of solidification. We especially wish to express our appreciation for the team around Georg Schmitz and Margret Nienhaus organising this event and giving us their valued advice and support at every stage in preparing the conference. We also thank Lokasenna Lektorat for taking the task of checking all language-associated issues and fixing the papers according to the templates given by IOP Conference Series. We also wish to express our gratitude to the IOP Conference Series publishers, who were always helpful and patient with us. Conference photograph

Numerical Modeling of HgCdTe Solidification: Effects of Phase Diagram, Double-Diffusion Convection and Microgravity Level

NASA Technical Reports Server (NTRS)

Bune, Andris V.; Gillies, Donald C.; Lehoczky, Sandor L.

1997-01-01

Melt convection, along with species diffusion and segregation on the solidification interface are the primary factors responsible for species redistribution during HgCdTe crystal growth from the melt. As no direct information about convection velocity is available, numerical modeling is a logical approach to estimate convection. Furthermore influence of microgravity level, double-diffusion and material properties should be taken into account. In the present study, HgCdTe is considered as a binary alloy with melting temperature available from a phase diagram. The numerical model of convection and solidification of binary alloy is based on the general equations of heat and mass transfer in two-dimensional region. Mathematical modeling of binary alloy solidification is still a challenging numericial problem. A Rigorous mathematical approach to this problem is available only when convection is not considered at all. The proposed numerical model was developed using the finite element code FIDAP. In the present study, the numerical model is used to consider thermal, solutal convection and a double diffusion source of mass transport.

A Three-Stage Mechanistic Model for Solidification Cracking During Welding of Steel

NASA Astrophysics Data System (ADS)

Aucott, L.; Huang, D.; Dong, H. B.; Wen, S. W.; Marsden, J.; Rack, A.; Cocks, A. C. F.

2018-03-01

A three-stage mechanistic model for solidification cracking during TIG welding of steel is proposed from in situ synchrotron X-ray imaging of solidification cracking and subsequent analysis of fracture surfaces. Stage 1—Nucleation of inter-granular hot cracks: cracks nucleate inter-granularly in sub-surface where maximum volumetric strain is localized and volume fraction of liquid is less than 0.1; the crack nuclei occur at solute-enriched liquid pockets which remain trapped in increasingly impermeable semi-solid skeleton. Stage 2—Coalescence of cracks via inter-granular fracture: as the applied strain increases, cracks coalesce through inter-granular fracture; the coalescence path is preferential to the direction of the heat source and propagates through the grain boundaries to solidifying dendrites. Stage 3—Propagation through inter-dendritic hot tearing: inter-dendritic hot tearing occurs along the boundaries between solidifying columnar dendrites with higher liquid fraction. It is recommended that future solidification cracking criterion shall be based on the application of multiphase mechanics and fracture mechanics to the failure of semi-solid materials.

Numerical analysis of thermal stress and dislocation density distributions in large size multi-crystalline silicon ingots during the seeded growth process

NASA Astrophysics Data System (ADS)

Nguyen, Thi Hoai Thu; Chen, Jyh-Chen; Hu, Chieh; Chen, Chun-Hung; Huang, Yen-Hao; Lin, Huang-Wei; Yu, Andy; Hsu, Bruce

2017-06-01

In this study, a global transient numerical simulation of silicon growth from the beginning of the solidification process until the end of the cooling process is carried out modeling the growth of an 800 kg ingot in an industrial seeded directional solidification furnace. The standard furnace is modified by the addition of insulating blocks in the hot zone. The simulation results show that there is a significant decrease in the thermal stress and dislocation density in the modified model as compared to the standard one (a maximal decrease of 23% and 75% along the center line of ingot for thermal stress and dislocation density, respectively). This modification reduces the heating power consumption for solidification of the silicon melt by about 17% and shortens the growth time by about 2.5 h. Moreover, it is found that adjusting the operating conditions of modified model to obtain the lower growth rate during the early stages of the solidification process can lower dislocation density and total heater power.

Fluid mechanics and solidification investigations in low-gravity environments

NASA Technical Reports Server (NTRS)

Fichtl, G. H.; Lundquist, C. A.; Naumann, R. J.

1980-01-01

Fluid mechanics of gases and liquids and solidification processes were investigated under microgravity conditions during Skylab and Apollo-Soyuz missions. Electromagnetic, acoustic, and aerodynamic levitation devices, drop tubes, aircraft parabolic flight trajectories, and vertical sounding rockets were developed for low-g simulation. The Spacelab 3 mission will be carried out in a gravity gradient flight attitude; analyses of sources of vehicle dynamic accelerations with associated g-levels and angular rates will produce results for future specific experiments.

Mechanism of Macrosegregation Formation in Continuous Casting Slab: A Numerical Simulation Study

NASA Astrophysics Data System (ADS)

Jiang, Dongbin; Wang, Weiling; Luo, Sen; Ji, Cheng; Zhu, Miaoyong

2017-12-01

Solidified shell bulging is supposed to be the main reason for slab center segregation, while the influence of thermal shrinkage rarely has been considered. In this article, a thermal shrinkage model coupled with the multiphase solidification model is developed to investigate the effect of the thermal shrinkage, solidification shrinkage, grain sedimentation, and thermal flow on solute transport in the continuous casting slab. In this model, the initial equiaxed grains contract freely with the temperature decrease, while the coherent equiaxed grains and columnar phase move directionally toward the slab surface. The results demonstrate that the center positive segregation accompanied by negative segregation in the periphery zone is mainly caused by thermal shrinkage. During the solidification process, liquid phase first transports toward the slab surface to compensate for thermal shrinkage, which is similar to the case considering solidification shrinkage, and then it moves opposite to the slab center near the solidification end. It is attributed to the sharp decrease of center temperature and the intensive contract of solid phase, which cause the enriched liquid to be squeezed out. With the effect of grain sedimentation and thermal flow, the negative segregation at the external arc side (zone A1) and the positive segregation near the columnar-to-equiaxed transition at the inner arc side (position B1) come into being. Besides, it is found that the grain sedimentation and thermal flow only influence solute transport before equiaxed grains impinge with each other, while the solidification and thermal shrinkage still affect solute redistribution in the later stage.

Evidence for Radial Anisotropy in Earth's Upper Inner Core from Normal Modes

NASA Astrophysics Data System (ADS)

Lythgoe, K.; Deuss, A. F.

2017-12-01

The structure of the uppermost inner core is related to solidification of outer core material at the inner core boundary. Previous seismic studies using body waves indicate an isotropic upper inner core, although radial anisotropy has not been considered since it cannot be uniquely determined by body waves. Normal modes, however, do constrain radial anisotropy in the inner core. Centre frequency measurements indicate 2-5 % radial anisotropy in the upper 100 km of the inner core, with a fast direction radially outwards and a slow direction along the inner core boundary. This seismic structure provides constraints on solidification processes at the inner core boundary and appears consistent with texture predicted due to anisotropic inner core growth.

Thermoelectric and morphological effects of Peltier pulsing on directional solidification of eutectic Bi-Mn

NASA Technical Reports Server (NTRS)

Silberstein, R. P.; Larson, D. J., Jr.; Dressler, B.

1984-01-01

Extensive in situ thermal measurements using Peltier Interface Demarcation (PID) during directional solidification of eutectic Bi/MnBi were carried out. Observations indicate that significant thermal transients occur throughout the sample as a result of the Peltier pulsing. The contributions of the Peltier, Thomson, and Joule heats were separated and studied as a function of pulse intensity and polarity. The Joule and the combined Peltier and Thomson thermal contributions were determined as a function of time during and after the current pulses, close to the solid/liquid interface. Variations of the Bi/MnBi particle morphology clearly reveal the interface shape, changes in interface velocity, meltback, and temporary loss of cooperative growth, as a result of the pulsing.

Artificial Bone and Teeth through Controlled Ice Growth in Colloidal Suspensions

NASA Astrophysics Data System (ADS)

Tomsia, Antoni P.; Saiz, Eduardo; Deville, Sylvain

2007-06-01

The formation of regular patterns is a common feature of many solidification processes involving cast materials. We describe here how regular patterns can be obtained in porous alumina and hydroxyapatite (HAP) by controlling the freezing of ceramic slurries followed by subsequent ice sublimation and sintering, leading to multilayered porous ceramic structures with homogeneous and well-defined architecture. These porous materials can be infiltrated with a second phase of choice to yield biomimetic nacre-like composites with improved mechanical properties, which could be used for artificial bone and teeth applications. Proper control of the solidification patterns provides powerful means of control over the final functional properties. We discuss the relationships between the experimental results, ice growth fundamentals, the physics of ice and the interaction between inert particles and the solidification front during directional freezing.

Artificial Bone and Teeth through Controlled Ice Growth in Colloidal Suspensions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tomsia, Antoni P.; Saiz, Eduardo; Deville, Sylvain

2007-06-14

The formation of regular patterns is a common feature of many solidification processes involving cast materials. We describe here how regular patterns can be obtained in porous alumina and hydroxyapatite (HAP) by controlling the freezing of ceramic slurries followed by subsequent ice sublimation and sintering, leading to multilayered porous ceramic structures with homogeneous and well-defined architecture. These porous materials can be infiltrated with a second phase of choice to yield biomimetic nacre-like composites with improved mechanical properties, which could be used for artificial bone and teeth applications. Proper control of the solidification patterns provides powerful means of control over themore » final functional properties. We discuss the relationships between the experimental results, ice growth fundamentals, the physics of ice and the interaction between inert particles and the solidification front during directional freezing.« less

Microstructural Characterization of a Directionally-Solidified Ni-33 (at. %)Al-31Cr-3Mo Eutectic Alloy as a Function of Withdrawal Rate

NASA Technical Reports Server (NTRS)

Raj, S. V.; Locci, I. E.; Whittenberger, J. D.; Salem, J. A.

2000-01-01

The Ni-33 (at. %)Al-3lCr-3Mo eutectic alloy was directionally-solidified (DS) at different rates, V(sub I), varying between 2.5 to 508 mm/ h. Detailed qualitative and quantitative metallographic and chemical analyses were conducted on the directionally-solidified rods. The microstructures consisted of eutectic colonies with parallel lamellar NiAl/(Cr,Mo) plates for solidification rates at and below 12.7 mm/ h. Cellular eutectic microstructures were observed at higher solidification rates, where the plates exhibited a radial pattern. The microstructures were demonstrated to be fairly uniform throughout a 100 mm length of the DS zone by quantitative metallography. The average cell size, bar-d, decreased with increasing growth rate to a value of 125 microns at 508 mm/ h according to the relation bar-d (microns) approx. = 465 V(sup -0.22, sub I), where V(sub I) is in mm/ h. Both the average NiAl plate thickness, bar-Delta(sub NiAl), and the interlamellar spacing, bar-lambda, were observed to be constant for V(sub I) less than or = 50.8 mm/ h but decreased with increasing growth rate above this value as 0.93 bar-Delta(sub NiAl)(microns) = 61.2 V(sup -0.93, sub I) and bar-lambda (microns) = 47.7 V(sup -0.64, sub I), respectively. The present results are detailed on a microstructural map. Keywords Optical microscopy, microstructure, compounds intermetallic, directional solidification

Dendritic Alloy Solidification Experiment (DASE)

NASA Technical Reports Server (NTRS)

Beckermann, C.; Karma, A.; Steinbach, I.; deGroh, H. C., III

2001-01-01

A space experiment, and supporting ground-based research, is proposed to study the microstructural evolution in free dendritic growth from a supercooled melt of the transparent model alloy succinonitrile-acetone (SCN-ACE). The research is relevant to equiaxed solidification of metal alloy castings. The microgravity experiment will establish a benchmark for testing of equiaxed dendritic growth theories, scaling laws, and models in the presence of purely diffusive, coupled heat and solute transport, without the complicating influences of melt convection. The specific objectives are to: determine the selection of the dendrite tip operating state, i.e. the growth velocity and tip radius, for free dendritic growth of succinonitrile-acetone alloys; determine the growth morphology and sidebranching behavior for freely grown alloy dendrites; determine the effects of the thermal/solutal interactions in the growth of an assemblage of equiaxed alloy crystals; determine the effects of melt convection on the free growth of alloy dendrites; measure the surface tension anisotropy strength of succinon itrile -acetone alloys establish a theoretical and modeling framework for the experiments. Microgravity experiments on equiaxed dendritic growth of alloy dendrites have not been performed in the past. The proposed experiment builds on the Isothermal Dendritic Growth Experiment (IDGE) of Glicksman and coworkers, which focused on the steady growth of a single crystal from pure supercooled melts (succinonitrile and pivalic acid). It also extends the Equiaxed Dendritic Solidification Experiment (EDSE) of the present investigators, which is concerned with the interactions and transients arising in the growth of an assemblage of equiaxed crystals (succinonitrile). However, these experiments with pure substances are not able to address the issues related to coupled heat and solute transport in growth of alloy dendrites.

Microstructural Quantification of Rapidly Solidified Undercooled D2 Tool Steel

NASA Astrophysics Data System (ADS)

Valloton, J.; Herlach, D. M.; Henein, H.; Sediako, D.

2017-10-01

Rapid solidification of D2 tool steel is investigated experimentally using electromagnetic levitation (EML) under terrestrial and reduced gravity conditions and impulse atomization (IA), a drop tube type of apparatus. IA produces powders 300 to 1400 μm in size. This allows the investigation of a large range of cooling rates ( 100 to 10,000 K/s) with a single experiment. On the other hand, EML allows direct measurements of the thermal history, including primary and eutectic nucleation undercoolings, for samples 6 to 7 mm in diameter. The final microstructures at room temperature consist of retained supersaturated austenite surrounded by eutectic of austenite and M7C3 carbides. Rapid solidification effectively suppresses the formation of ferrite in IA, while a small amount of ferrite is detected in EML samples. High primary phase undercoolings and high cooling rates tend to refine the microstructure, which results in a better dispersion of the eutectic carbides. Evaluation of the cell spacing in EML and IA samples shows that the scale of the final microstructure is mainly governed by coarsening. Electron backscattered diffraction (EBSD) analysis of IA samples reveals that IA powders are polycrystalline, regardless of the solidification conditions. EBSD on EML samples reveals strong differences between the microstructure of droplets solidified on the ground and in microgravity conditions. While the former ones are polycrystalline with many different grains, the EML sample solidified in microgravity shows a strong texture with few much larger grains having twinning relationships. This indicates that fluid flow has a strong influence on grain refinement in this system.

Solidification studies of nanocrystalline and quasicrystalline materials from the undercooled state

NASA Astrophysics Data System (ADS)

Croat, Thomas Kevin

2001-07-01

Nanocrystallization occurring during metallic glass devitrification is studied in Zr-Al-Ni-Cu bulk metallic glasses (BMGs) and Al-RE-TM (RE = rare-earth, TM = transition metal) metallic glasses. The importance of transient nucleation in BMG devitrification was established by a direct transmission electron microscopy (TEM) measurement of the grain density in two-stage annealed samples. TEM examination of low temperature annealed BMGs also suggest that amorphous phase separation is occurring prior to crystallization. Nanocrystallization of rapidly quenched Al-RE-Ni glasses was preceded by the compositional segregation of the initially homogeneous glass into Al-rich and solute-rich regions (mainly nickel-enriched) on a ≈50--100 nm length scale, suggesting amorphous phase separation. This pre-existing compositional modulation on a nanometer scale leads naturally to the development of nanocrystals. The average rare earth radius (rRE) in Al-RE-Ni alloys was altered by co-substitution of chemically similar rare earth elements. In glasses with smaller r RE, nucleation of alpha-Al occurred preferentially near the boundaries of the phase-separated regions. However, phase separation did not universally lead to alpha-Al nanocrystallization; glasses with larger rRE crystallized to metastable intermetallic phases with a 50--100 nm grain size. Kinetic analysis of the alpha-Al crystallization was performed using isothermal DSC, yielding abnormally low Avrami exponents (n = 1.0--1.5); these values were found to be consistent with the observed transformation using a model that considers the overlapping diffusion fields of the alpha-Al grains during growth within the phase separated region. Containerless solidification experiments on Ti-based quasicrystal-forming alloys have been performed using various techniques, including drop-tube solidification, electromagnetic levitation (EML) and electrostatic levitation (ESL). In Ti-Fe-Si-O, the alpha-1/1 quasicrystal approximant phase is found to nucleate directly from the liquid over the range TixFe94-xSi 4(SiO2)2 with 67 < x < 69 in EML experiments. Both the alpha-1/1 phase in Ti-Fe-Si-O and the C14 Laves phase in Ti-Zr-Ni have lower relative undercoolings than nearby crystal phases. This presumably reflects the structural similarity between these polytetrahedral phases and the undercooled liquid, which leads to smaller nucleation barriers and lower maximum undercoolings.

Divorced Eutectic Solidification of Mg-Al Alloys

NASA Astrophysics Data System (ADS)

Monas, Alexander; Shchyglo, Oleg; Kim, Se-Jong; Yim, Chang Dong; Höche, Daniel; Steinbach, Ingo

2015-08-01

We present simulations of the nucleation and equiaxed dendritic growth of the primary hexagonal close-packed -Mg phase followed by the nucleation of the -phase in interdendritic regions. A zoomed-in region of a melt channel under eutectic conditions is investigated and compared with experiments. The presented simulations allow prediction of the final properties of an alloy based on process parameters. The obtained results give insight into the solidification processes governing the microstructure formation of Mg-Al alloys, allowing their targeted design for different applications.

Melting-solidification transition of Zn nanoparticles embedded in SiO2: Observation by synchrotron x-ray and ultraviolet-visible-near-infrared light

NASA Astrophysics Data System (ADS)

Amekura, H.; Tanaka, M.; Katsuya, Y.; Yoshikawa, H.; Ohnuma, M.; Matsushita, Y.; Kobayashi, K.; Kishimoto, N.

2010-11-01

Melting-solidification transition of Zn nanoparticles (NPs) with the mean diameter of 11.5 nm, embedded in silica glass, was investigated by glancing incident x-ray diffraction (GIXRD) at high temperatures using synchrotron radiation (SR). With increasing temperature, 101Zn diffraction peak gradually decreases up to ˜360 °C and then steeply decreases. This is due to the melting of Zn NPs, which completes around 420 °C. With decreasing temperature, the solidification of the NPs begins around ˜310 °C. The temperature hysteresis with a width of ˜110 °C was observed. With temperature, the diffraction angle shows a shift without hysteresis, which is ascribed to thermal expansion of Zn NP lattice. Thermal expansion coefficient of Zn NPs was determined as 24.4×10-6 K-1 along the ⟨101⟩ direction. Optical absorption spectroscopy shows a broad ultraviolet (UV) peak which was observed at even higher temperatures than the melting temperature but shifts to the low-energy side with the melting. The energy shift in the UV peak also shows the temperature hysteresis which resembles with the melting-solidification hysteresis recorded by SR-GIXRD. The melting-solidification transition is also detectable by the optical absorption spectroscopy in the UV-visible-near-infrared region.

Astronaut Peggy Whitson Installs SUBSA Experiment

NASA Technical Reports Server (NTRS)

2002-01-01

Expedition Five flight engineer Peggy Whitson is shown installing the Solidification Using a Baffle in Sealed Ampoules (SUBSA) experiment in the Microgravity Science Glovebox (MSG) in the Destiny laboratory aboard the International Space Station (ISS). SUBSA examines the solidification of semiconductor crystals from a melted material. Semiconductor crystals are used for many products that touch our everyday lives. They are found in computer chips, integrated circuits, and a multitude of other electronic devices, such as sensors for medical imaging equipment and detectors of nuclear radiation. Materials scientists want to make better semiconductor crystals to be able to further reduce the size of high-tech devices. In the microgravity environment, convection and sedimentation are reduced, so fluids do not remove and deform. Thus, space laboratories provide an ideal environment of studying solidification from the melt. This investigation is expected to determine the mechanism causing fluid motion during production of semiconductors in space. It will provide insight into the role of the melt motion in production of semiconductor crystals, advancing our knowledge of the crystal growth process. This could lead to a reduction of defects in semiconductor crystals produced in space and on Earth.

Assessment of the leaching of metallic elements in the technology of solidification in aqueous solution.

PubMed

Rossetti, V Alunno; Di Palma, L; Medici, F

2002-01-01

Results are presented of experiments performed to optimize the solidification/stabilization system for metallic elements in aqueous solution. This system involves mixing cement and a solution of metallic elements in a conventional mixer: the paste thus obtained is transferred drop by drop into a recipient filled with an aqueous solution of NaOH at 20% by weight, in which it solidifies immediately. The separate use of chloride solutions of Li+, Cr3+, Pb2+ and Zn2+ makes it possible to obtain granules displaying various levels of compressive strength. Three different inertization matrices were used in the experiments, the first consisting solely of Portland cement, the second of Portland cement and a superplasticizer additive, and the third of Portland cement partially replaced with silica-fume and superplasticizer. The results of the tests performed showed a very low level of leaching into the alkaline solidification solution for Cr3+, the quantity leached being under 2% as against higher levels for the other metallic elements. For all the considered elements, the best results were obtained by using silica-fume in the inertization matrix.

NBS (National Bureau of Standards): Materials measurements

NASA Technical Reports Server (NTRS)

Manning, J. R.

1984-01-01

Work in support of NASA's Microgravity Science and Applications Program is described. The results of the following three tasks are given in detail: (1) surface tensions and their variations with temperature and impurities; (2) convection during unidirectional solidification; and (3) measurement of high temperature thermophysical properties. Tasks 1 and 2 were directed toward determining how the reduced gravity obtained in space flight can affect convection and solidification processes. Emphasis in task 3 was on development of levitation and containerless processing techniques which can be applied in space flight to provide thermodynamic measurements of reactive materials.

Cellular interface morphologies in directional solidification. II - The effect of grain boundaries

NASA Technical Reports Server (NTRS)

Ungar, Lyle H.; Brown, Robert A.

1984-01-01

A singular perturbation analysis valid for small grain-boundary slopes is used with the one-sided model for solidification to show that grain boundaries introduce imperfections into the symmetry of the developing cellular interfaces which rupture the junction between the family of planar shapes and the bifurcating cellular families. Undulating interfaces are shown to develop first near grain boundaries, and to evolve with decreasing temperature gradient either by a smooth transition from the almost planar family or by a sudden jump to moderate-amplitude cellular forms, depending on the growth rate.

A thermodynamic prediction for microporosity formation in aluminum-rich Al-Cu alloys

NASA Technical Reports Server (NTRS)

Poirier, D. R.; Yeum, K.; Maples, A. L.

1987-01-01

A computer model is used to predict the formation and degree of microporosity in a directionally solidified Al-4.5 wt pct Cu alloy, considering the interplay between solidification shrinkage and gas porosity. Macrosegregation theory is used to determine the local pressure within the interdendritic liquid. Results show interdendritic porosity for initial hydrogen contents in the 0.03-1 ppm range, and none below contents of 0.03. An increase in either the thermal gradient or the solidification rate is show to decrease the amount of interdendritic porosity.

Influence of Bridgman solidification on microstructures and magnetic behaviors of a non-equiatomic FeCoNiAlSi high-entropy alloy

DOE PAGES

Zuo, Tingting; Yang, Xiao; Liaw, Peter K.; ...

2015-09-07

The non-equiatomic FeCoNiAlSi alloy is prepared by the Bridgman solidification (BS) technique at different withdrawal velocities (V = 30, 100, and 200 μm/s). Various characterization techniques have been used to study the microstructure and crystal orientation. The morphological evolutions accompanying the crystal growth of the alloy prepared at different withdrawal velocities are nearly the same, from equiaxed grains to columnar crystals. The transition of coercivity is closely related to the local microstructure, while the saturation magnetization changes little at different sites. The coercivity can be significantly reduced from the equiaxed grain area to the columnar crystal area when the appliedmore » magnetic field direction is parallel to the crystal growth direction, no matter what is the withdrawal velocity. As a result, the alloy possesses magnetic anisotropy when the applied magnetic field is in different directions.« less

Project Explorer: Get Away Special #007. [alloy solidification, seed germination, crystal growth, and radio transmission of payload data

NASA Technical Reports Server (NTRS)

Henderson, A. J., Jr.

1984-01-01

Tentatively scheduled to fly on STS-17 (41G), this get away special aims to demonstrate amateur radio transmissions to global ground stations in the English language. Experiments No. 1, 2, and 3 use the micro-gravity of space flight to study the solidification of lead-antimony and aluminum-copper alloys, the germination of radish seeds, and the growth of potassium-tetracyanoplatinate hydrate crystals in an aqueous solution. Flight results are to be compared with Earth-based data. Experiment No. 4 (the Marshall Amateur Radio Club Experiment - MARCE) features radio transmissions and also provides timing for the start of all other experiments. A microprocessor obtains real-time data from all experiments as well as temperature and pressure measurements within the GAS canister. These data are to be transmitted on previously announced amateur radio frequencies after they are converted into the English language by a digitalker for general reception. The support structure for the G #007 experiments consists of two primary plates and four bumper assemblies.

Primary Dendrite Array Morphology: Observations from Ground-based and Space Station Processed Samples

NASA Technical Reports Server (NTRS)

Tewari, Surendra; Rajamure, Ravi; Grugel, Richard; Erdmann, Robert; Poirier, David

2012-01-01

Influence of natural convection on primary dendrite array morphology during directional solidification is being investigated under a collaborative European Space Agency-NASA joint research program, "Microstructure Formation in Castings of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions (MICAST)". Two Aluminum-7 wt pct Silicon alloy samples, MICAST6 and MICAST7, were directionally solidified in microgravity on the International Space Station. Terrestrially grown dendritic monocrystal cylindrical samples were remelted and directionally solidified at 18 K/cm (MICAST6) and 28 K/cm (MICAST7). Directional solidification involved a growth speed step increase (MICAST6-from 5 to 50 micron/s) and a speed decrease (MICAST7-from 20 to 10 micron/s). Distribution and morphology of primary dendrites is currently being characterized in these samples, and also in samples solidified on earth under nominally similar thermal gradients and growth speeds. Primary dendrite spacing and trunk diameter measurements from this investigation will be presented.

Primary Dendrite Array: Observations from Ground-Based and Space Station Processed Samples

NASA Technical Reports Server (NTRS)

Tewari, Surendra N.; Grugel, Richard N.; Erdman, Robert G.; Poirier, David R.

2012-01-01

Influence of natural convection on primary dendrite array morphology during directional solidification is being investigated under a collaborative European Space Agency-NASA joint research program, Microstructure Formation in Castings of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions (MICAST). Two Aluminum-7 wt pct Silicon alloy samples, MICAST6 and MICAST7, were directionally solidified in microgravity on the International Space Station. Terrestrially grown dendritic monocrystal cylindrical samples were remelted and directionally solidified at 18 K per centimeter (MICAST6) and 28 K per centimeter (MICAST7). Directional solidification involved a growth speed step increase (MICAST6-from 5 to 50 millimeters per second) and a speed decrease (MICAST7-from 20 to 10 millimeters per second). Distribution and morphology of primary dendrites is currently being characterized in these samples, and also in samples solidified on earth under nominally similar thermal gradients and growth speeds. Primary dendrite spacing and trunk diameter measurements from this investigation will be presented.

Lattice relations and solidification of the complex regular eutectic (Cr,Fe)-(Cr,Fe)23C6

NASA Astrophysics Data System (ADS)

Lai, Hsuan-Han; Hsieh, Chih-Chun; Lin, Chi-Ming; Wu, Weite

2017-05-01

The eutectic (Cr,Fe)-(Cr,Fe)23C6 showed a triaxial fishbone structure and could be categorized as a "complex regular structure". In this study, the lattice relations of the fishbone (Cr,Fe)23C6 were examined and the solidification process was observed using a transmission electron microscope and a confocal laser scanning microscope. For one of the three fish bones in a eutectic cell, parallel (Cr,Fe)23C6 lamellas at one side of the spine had the same lattice direction, as did those in the (Cr,Fe) phase. The lattices of neighboring (Cr,Fe)23C6 and (Cr,Fe) phases were not coherent. Lamellar (Cr,Fe)23C6 on opposite sides of a spine had different lattice directions, and their lattice boundary was in the spine. By using the confocal laser scanning microscope, the solidification of lamellar eutectic structure could be observed. At the low cooling rate of 5 o C·min-1, parallel lamellas would grow thick blocks instead of thin plates. To obtain a thin lamellar eutectic structure, the cooling rate should be higher, like the rate in welding.

Microstructure and Tensile/Corrosion Properties Relationships of Directionally Solidified Al-Cu-Ni Alloys

NASA Astrophysics Data System (ADS)

Rodrigues, Adilson V.; Lima, Thiago S.; Vida, Talita A.; Brito, Crystopher; Garcia, Amauri; Cheung, Noé

2018-03-01

Al-Cu-Ni alloys are of scientific and technological interest due to high strength/high temperature applications, based on the reinforcement originated from the interaction between the Al-rich phase and intermetallic composites. The nature, morphology, size, volume fraction and dispersion of IMCs particles throughout the Al-rich matrix are important factors determining the resulting mechanical and chemical properties. The present work aims to evaluate the effect of the addition of 1wt%Ni into Al-5wt%Cu and Al-15wt%Cu alloys on the solidification rate, macrosegregation, microstructure features and the interrelations of such characteristics on tensile and corrosion properties. A directional solidification technique is used permitting a wide range of microstructural scales to be examined. Experimental growth laws relating the primary and secondary dendritic spacings to growth rate and solidification cooling rate are proposed, and Hall-Petch type equations are derived relating the ultimate tensile strength and elongation to the primary dendritic spacing. Considering a compromise between ultimate tensile strength and corrosion resistance of the examined alloys samples from both alloys castings it is shown that the samples having more refined microstructures are associated with the highest values of such properties.

Exploiting the Temperature/Concentration Dependence of Magnetic Susceptibility to Control Convection in Fundamental Studies of Solidification Phenomena

NASA Technical Reports Server (NTRS)

Evans, J. W.; Xu, Dong; Jones, W. Kinzy, Jr.; Szofran, Frank R.

1999-01-01

The objective of this new research project is to demonstrate by experiment, supplemented by mathematical modeling and physical property measurement, that the effects of buoyancy driven convection can be largely eliminated in ground-based experiments, and further reduced in flight, by applying a new technique. That technique exploits the dependence of magnetic susceptibility on composition or temperature. It is emphasized at the outset that the phenomenon to be exploited is fundamentally and practically different from the magnetic damping of convection in conducting liquids that has been the subject of much prior research. The concept suggesting this research is that all materials, even non-conductors, when placed in a magnetic field gradient, experience a force. Of particular interest here are paramagnetic and diamagnetic materials, classes which embrace the "model alloys", such as succinonitrile-acetone, that have been used by others investigating the fundamentals of solidification. Such alloys will exhibit a dependence of susceptibility on composition. The consequence is that, with a properly oriented field (gradient) a force will arise that can be made to be equal to, but opposite, the buoyancy force arising from concentration (or temperature) gradients. In this way convection can be stilled. The role of convection in determining the microstructure, and thereby properties, of materials is well known. Elimination of that convection has both scientific and technological consequences. Our knowledge of diffusive phenomena in solidification, phenomena normally hidden by the dominance of convection, is enhanced if we can study solidification of quiescent liquids. Furthermore, the microstructure, microchemistry and properties of materials (thereby practical value) are affected by the convection occurring during their solidification. Hitherto the method of choice for elimination of convection has been experimentation in microgravity. However, even in low Earth orbit, residual convection has effects. That residual convection arises from acceleration (drag on the spacecraft), displacement from the center of mass or transients in the gravitational field (g-jitter). There is therefore a need for both further reducing buoyancy driven flow in flight and allowing the simulation of microgravity during ground based experiments. Previous investigations, the research project description, theory behind the study and experimental methods as well as plots of magnetic fields and forces are presented.

Compositional redistribution during casting of Hg sub 0.8 Cd sub 0.2 Te alloys

NASA Technical Reports Server (NTRS)

Su, Ching-Hua; Perry, G. L. E.; Szofran, F. R.; Lehoczky, S. L.

1986-01-01

A series of Hg(0.8)Cd(0.2)Te ingots was cast both vertically and horizontally under well-defined thermal conditions by using a two-zone furnace with isothermal heat-pipe liners. The main objective of the experiments was to establish correlations between casting parameters and compositional redistribution and to develop ground-based data for a proposed flight experiment of casting of Hg(1-x)Cd(x)Te alloys under reduced gravity conditions. The compositional variations along the axial and radial directions were determined by precision density measurements, infrared transmission spectra, and X-ray energy dispersion spectrometry. Comparison between the experimental results and a numerical simulation of the solidification process of Hg(0.8)Cd(0.2)Te is described.

Formation mechanism of axial macrosegregation of primary phases induced by a static magnetic field during directional solidification

PubMed Central

Li, Xi; Fautrelle, Yves; Ren, Zhongming; Moreau, Rene

2017-01-01

Understanding the macrosegregation formed by applying magnetic fields is of high commercial importance. This work investigates how static magnetic fields control the solute and primary phase distributions in four directionally solidified alloys (i.e., Al-Cu, Al-Si, Al-Ni and Zn-Cu alloys). Experimental results demonstrate that significant axial macrosegregation of the solute and primary phases (i.e., Al2Cu, Si, Al3Ni and Zn5Cu phases) occurs at the initial solidification stage of the samples. This finding is accompanied by two interface transitions in the mushy zone: quasi planar → sloping → quasi planar. The amplitude of the macrosegregation of the primary phases under the magnetic field is related to the magnetic field intensity, temperature gradient and growth speed. The corresponding numerical simulations present a unidirectional thermoelectric (TE) magnetic convection pattern in the mushy zone as a consequence of the interaction between the magnetic field and TE current. Furthermore, a model is proposed to explain the peculiar macrosegregation phenomenon by considering the effect of the forced TE magnetic convection on the solute distribution. The present study not only offers a new approach to control the solute distribution by applying a static magnetic field but also facilitates the understanding of crystal growth in the solute that is controlled by the static magnetic field during directional solidification. PMID:28367991

The structure of melting mushy zones, with implications for Earth's inner core (Invited)

NASA Astrophysics Data System (ADS)

Bergman, M. I.; Huguet, L.; Alboussiere, T.

2013-12-01

Seismologists have inferred hemispherical differences in the isotropic wavespeed, the elastic anisotropy, the attenuation, and the attenuation anisotropy of Earth's inner core. One hypothesis for these hemispherical differences involves an east-west translation of the inner core, with enhanced solidification on one side and melting on the other. Another hypothesis is that long term mantle control over outer core convection can lead to hemispherical variations in solidification that could even result in melting in some regions of the inner core boundary. It has also been hypothesized that the inner core is growing dendritically, resulting in an inner core that has the structure of a mushy zone (albeit one with a high solid fraction). It would therefore be helpful to understand how the structure of a melting mushy zone might look in comparison with one that is solidifying, in an effort to help interpret the seismic inferences. We have carried out experiments on the solidification of ammonium chloride from an aqueous solution, yielding a mushy zone. The experiments run in a centrifuge, in order to reach a more realistic ratio of convective velocity to phase change rate, expected to be very large at the boundary of the inner core. Hypergravity thus increases the experimental solid fraction of the mush. So far the maximum gravity we have achieved is 200 g. A Peltier cell provides cooling at one end of the cell, and after the mushy zone has grown we turn on a heater at the other end. Probes monitor the temperature along the height of the cell. As ammonium chloride in the mushy zone melts it produces more dense fluid, which results in convection in the mushy zone, a greater ammonium chloride concentration deeper in the mushy zone, and hence enhanced solidification there. This thus changes the solid fraction profile from that during solidification, which may be observable in the lab experiments using ultrasonic transducers and post-mortem under a microscope. The melting may also change the propagation of chimney convection. It remains unclear whether these changes will be observable seismically.

Effect of Marangoni Convection Generated by Voids on Segregation During Low-G and 1-G Solidification

NASA Technical Reports Server (NTRS)

Kassemi, M.; Fripp, A.; Rashidnia, N.; deGroh, H.

2001-01-01

Solidification experiments, especially microgravity solidification experiments, are often compromised by the evolution of unwanted voids or bubbles in the melt. Although these voids and/or bubbles are highly undesirable, there is currently no effective means of preventing their formation or of eliminating their adverse effects, particularly during microgravity experiments. Marangoni convection caused by these voids can drastically change the transport processes in the melt. Recent microgravity experiments by Matthiesen (1) Andrews (2) and Fripp (3) are perfect examples of how voids and bubbles can affect the outcome of costly space experiments and significantly increase the level of difficulty in interpreting their results. Formation of bubbles have caused problems in microgravity experiments for a long time. Even in the early Skylab mission an unexpectedly large number of bubbles were detected in the four materials processing experiments reported by Papazian and Wilcox (4). They demonstrated that while during ground-based tests bubbles were seen to detach from the interface easily and float to the top of the melt, in low-gravity tests no detachment from the interface occurred and large voids were grown in the crystal. More recently, the lead-tin-telluride crystal growth experiment of Fripp et al.(3) flown aboard the USMP-3 mission has provided very interesting results. The purpose of the study was to investigate the effect of natural convection on the solidification process by growing the samples at different orientations with respect to the gravitational field. Large pores and voids were found in the three solid crystal samples processed in space. Post-growth characterization of the compositional profiles of the cells indicated considerable levels of mixing even in the sample grown in the hot-on-top stable configuration. The mixing was attributed to thermocapillary convection caused by the voids and bubbles which evolved during growth. Since the thermocapillary convection is orientation-independent, diffusion-controlled growth was not possible in any of the samples, even the top-heated one. These results are consistent with recent studies of thermocapillary convection generated by a bubble on a heated surface undertaken by Kassemi and Rashidnia (5-7) where it is numerically and experimentally shown that the thermocapillary flow generated by a bubble in a model fluid (silicone oil) can drastically modify the temperature field through vigorous mixing of the fluid around it, especially under microgravity conditions.

An initial study of void formation during solidification of aluminum in normal and reduced-gravity

NASA Technical Reports Server (NTRS)

Chiaramonte, Francis P.; Foerster, George; Gotti, Daniel J.; Neumann, Eric S.; Johnston, J. C.; De Witt, Kenneth J.

1992-01-01

Void formation due to volumetric shrinkage during aluminum solidification was observed in real time using a radiographic viewing system in normal and reduced gravity. An end chill directional solidification furnace with water quench was developed to solidify aluminum samples during the approximately 16 seconds of reduced gravity (+/- 0.02g) achieved by flying an aircraft through a parabolic trajectory. Void formation was recorded for two cases: first a nonwetting system; and second, a wetting system where wetting occurs between the aluminum and crucible lid. The void formation in the nonwetting case is similar in normal and reduced gravity, with a single vapor cavity forming at the top of the crucible. In the wetting case in reduced gravity, surface tension causes two voids to form in the top corners of the crucible, but in normal gravity only one large voids forms across the top.

Influence of solidification accelerators on structure formation of anhydrite-containing binders

NASA Astrophysics Data System (ADS)

Anikanova, L.; Volkova, O.; Kudyakov, A.; Sarkisov, Y.; Tolstov, D.

2016-01-01

The article presents results of scientific analysis of chemical additives influence on acid fluoride binder. It was found that the influence of sulfate nature additives on the process of hydration and solidification of the binder is similar to influence of additives on indissoluble anhydrite. Additives with SO42- anion NO- are more efficient. The mentioned additives according to accelerating effect belong to the following succession: K2SO4 > Na2SO4 > FeSO4 > MgSO4. Facilitation of the process of hydration and solidification of the binder, increase in density and durability of the binder (32 MPa) is to the greatest extent achieved with the introduction of 2% sodium sulfate additive of the binder's mass into the composition of the binder along with the ultrasonic treatment of water solution. Directed crystal formation process with healing of porous structure by new growths presented as calcium sulfate dehydrate and hydroglauberite provides positive effect.

Consequences of Part Temperature Variability in Electron Beam Melting of Ti-6Al-4V

NASA Astrophysics Data System (ADS)

Fisher, Brian A.; Mireles, Jorge; Ridwan, Shakerur; Wicker, Ryan B.; Beuth, Jack

2017-12-01

To facilitate adoption of Ti-6Al-4V (Ti64) parts produced via additive manufacturing (AM), the ability to ensure part quality is critical. Measuring temperatures is an important component of part quality monitoring in all direct metal AM processes. In this work, surface temperatures were monitored using a custom infrared camera system attached to an Arcam electron beam melting (EBM®) machine. These temperatures were analyzed to understand their possible effect on solidification microstructure based on solidification cooling rates extracted from finite element simulations. Complicated thermal histories were seen during part builds, and temperature changes occurring during typical Ti64 builds may be large enough to affect solidification microstructure. There is, however, enough time between fusion of individual layers for spatial temperature variations (i.e., hot spots) to dissipate. This means that an effective thermal control strategy for EBM® can be based on average measured surface temperatures, ignoring temperature variability.

Investigation of compositional segregation during unidirectional solidification of solid solution semiconducting alloys

NASA Technical Reports Server (NTRS)

Wang, J. C.

1982-01-01

Compositional segregation of solid solution semiconducting alloys in the radial direction during unidirectional solidification was investigated by calculating the effect of a curved solid liquid interface on solute concentration at the interface on the solid. The formulation is similar to that given by Coriell, Boisvert, Rehm, and Sekerka except that a more realistic cylindrical coordinate system which is moving with the interface is used. Analytical results were obtained for very small and very large values of beta with beta = VR/D, where V is the velocity of solidification, R the radius of the specimen, and D the diffusivity of solute in the liquid. For both very small and very large beta, the solute concentration at the interface in the solid C(si) approaches C(o) (original solute concentration) i.e., the deviation is minimal. The maximum deviation of C(si) from C(o) occurs for some intermediate value of beta.

Influence of non steady gravity on natural convection during micro-gravity solidification of semiconductors. I - Time scale analysis. II - Implications for crystal growth experiments

NASA Technical Reports Server (NTRS)

Griffin, P. R.; Motakef, S.

1989-01-01

Consideration is given to the influence of temporal variations in the magnitude of gravity on natural convection during unidirectional solidification of semiconductors. It is shown that the response time to step changes in g at low Rayleigh numbers is controlled by the momentum diffusive time scale. At higher Rayleigh numbers, the response time to increases in g is reduced because of inertial effects. The degree of perturbation of flow fields by transients in the gravitational acceleration on the Space Shuttle and the Space Station is determined. The analysis is used to derive the requirements for crystal growth experiments conducted on low duration low-g vehicles. Also, the effectiveness of sounding rockets and KC-135 aircraft for microgravity experiments is examined.

Insert Concepts for the Material Science Research Rack (MSRR-1) of the Material Science Research Facility (MSRF) on the International Space Station (ISS)

NASA Technical Reports Server (NTRS)

Crouch, Myscha; Carswell, Bill; Farmer, Jeff; Rose, Fred; Tidwell, Paul

2000-01-01

The Material Science Research Rack I (MSRR-1) of the Material Science Research Facility (MSRF) contains an Experiment Module (EM) being developed collaboratively by NASA and the European Space Agency (ESA). This NASA/ESA EM will accommodate several different removable and replaceable Module Inserts (MIs) which are installed on orbit NASA's planned inserts include the Quench Module Insert (QMI) and the Diffusion Module Insert (DMI). The QMI is a high-gradient Bridgman-type vacuum furnace with quench capabilities used for experiments on directional solidification of metal alloys. The DMI is a vacuum Bridgman-Stockbarger-type furnace for experiments on Fickian and Soret diffusion in liquids. This paper discusses specific design features and performance capabilities of each insert. The paper also presents current prototype QMI hardware analysis and testing activities and selected results.

Solution of free-boundary problems using finite-element/Newton methods and locally refined grids - Application to analysis of solidification microstructure

NASA Technical Reports Server (NTRS)

Tsiveriotis, K.; Brown, R. A.

1993-01-01

A new method is presented for the solution of free-boundary problems using Lagrangian finite element approximations defined on locally refined grids. The formulation allows for direct transition from coarse to fine grids without introducing non-conforming basis functions. The calculation of elemental stiffness matrices and residual vectors are unaffected by changes in the refinement level, which are accounted for in the loading of elemental data to the global stiffness matrix and residual vector. This technique for local mesh refinement is combined with recently developed mapping methods and Newton's method to form an efficient algorithm for the solution of free-boundary problems, as demonstrated here by sample calculations of cellular interfacial microstructure during directional solidification of a binary alloy.

A review of rapid solidification studies of intermetallic compounds

NASA Technical Reports Server (NTRS)

Koch, C. C.

1985-01-01

A review of rapid solidification studies of high-temperature ordered intermetallic compounds is presented. Emphasis is on the nickel - and iron- aluminides which are of potential interest as structural materials. The nickel-base aluminides which have been rapidly solidified exhibit changes in grain size, compositional segregation, and degree of long range order (as reflected in APB size and distribution) which markedly affect mechanical properties. Some experiments indicate the formation of a metastable L1(2) phase in rapidly solidified Fe-(Ni,Mn)-Al-C alloys, while other work observes only a metastable fcc phase in the same composition range. The metastable phases and/or microstructures in both nickel and iron aluminides are destroyed by annealing at temperatures above 750 K, with subsequent degradation of mechanical properties. Rapid solidification studies of several other intermetallic compounds are briefly noted.

Effect of Secondary Cooling Conditions on Solidification Structure and Central Macrosegregation in Continuously Cast High-Carbon Rectangular Billet

NASA Astrophysics Data System (ADS)

Zeng, Jie; Chen, Weiqing

2015-10-01

Solidification structures of high carbon rectangular billet with a size of 180 mm × 240 mm in different secondary cooling conditions were simulated using cellular automaton-finite element (CAFE) coupling model. The adequacy of the model was compared with the simulated and the actual macrostructures of 82B steel. Effects of the secondary cooling water intensity on solidification structures including the equiaxed grain ratio and the equiaxed grain compactness were discussed. It was shown that the equiaxed grain ratio and the equiaxed grain compactness changed in the opposite direction at different secondary cooling water intensities. Increasing the secondary cooling water intensity from 0.9 or 1.1 to 1.3 L/kg could improve the equiaxed grain compactness and decrease the equiaxed grain ratio. Besides, the industrial test was conducted to investigate the effect of different secondary cooling water intensities on the center carbon macrosegregation of 82B steel. The optimum secondary cooling water intensity was 0.9 L/kg, while the center carbon segregation degree was 1.10. The relationship between solidification structure and center carbon segregation was discussed based on the simulation results and the industrial test.

Solidification as low cost technology prior to land filling of industrial hazardous waste sludge.

PubMed

El-Sebaie, O; Ahmed, M; Ramadan, M

2000-01-01

The aim of this study is to stabilize and solidify two different treated industrial hazardous waste sludges, which were selected from factories situated close to Alexandria. They were selected to ensure their safe transportation and landfill disposal by reducing their potential leaching of hazardous elements, which represent significant threat to the environment, especially the quality of underground water. The selected waste sludges have been characterized. Ordinary Portland Cement (OPC), Cement Kiln Dust (CKD) from Alexandria Portland Cement Company, and Calcium Sulphate as a by-product from the dye industry were used as potential solidification additives to treat the selected treated waste sludges from tanning and dyes industry. Waste sludges as well as the solidified wastes have been leach-tested, using the General Acid Neutralization Capacity (GANC) procedure. Concentration of concerning metals in the leachates was determined to assess changes in the mobility of major contaminants. The treated tannery waste sludge has an acid neutralization capacity much higher than that of the treated dyes waste sludge. Experiment results demonstrated the industrial waste sludge solidification mix designs, and presented the reduction of contaminant leaching from two types of waste sludges. The main advantages of solidification are that it is simple and low cost processing which includes readily available low cost solidification additives that will convert industrial hazardous waste sludges into inert materials.

Large low-field magnetocaloric effect in directionally solidified Ni55Mn18+xGa27-x (x = 0, 1, 2) alloys

NASA Astrophysics Data System (ADS)

Li, Zhenzhuang; Li, Zongbin; Yang, Bo; Yang, Yiqiao; Zhang, Yudong; Esling, Claude; Zhao, Xiang; Zuo, Liang

2018-01-01

The magnetostructural transformation and magnetocaloric effect of directionally solidified polycrystalline Ni55Mn18+xGa27-x (x = 0, 1, 2) alloys were studied. It is shown the directionally solidified alloys form coarse columnar-shaped grains with strong 〈0 0 1〉A (the subscript A refers to austenite) preferred orientation along the solidification direction. Through Mn substitution for Ga, a coupled magnetostructural transformation was realized in Ni55Mn19Ga26 and Ni55Mn20Ga25 alloys. Large adiabatic temperature variation (ΔTad) of 1.47 K and 1.57 K under the low field change of 1.5 T were achieved in these two alloys, respectively. Such ΔTad values are obviously higher than that obtained from a single martensitic transformation and magnetic transition. The present results demonstrate that proper composition tuning to achieve magnetostructural transformation as well as increasing the grain size and preferential orientation degree through directional solidification could be an economical processing route to optimize magnetocaloric properties in polycrystalline Ni-Mn-Ga based alloys.

Exploiting the Temperature Dependence of Magnetic Susceptibility to Control Convective in Fundamental Studies of Solidification Phenomena

NASA Technical Reports Server (NTRS)

Seybert, C.; Evans, J. W.; Leslie, F.; Jones, W. K., Jr.

2001-01-01

It is well known that convection is a dominant mass transport mechanism when materials are solidified on Earth's surface. This convection is caused by gradients in density (and therefore gravitational force) that are brought about by gradients in temperature, composition or both. Diffusion of solute is therefore dwarfed by convection and the study of fundamental parameters, such as dendrite tip shape and growth velocity in the absence of convection is nearly impossible. Significant experimental work has therefore been carried out in orbiting laboratories with the intent of minimizing convection by minimizing gravity. One of the best known experiments of this kind is the Isothermal Dendritic Growth Experiment (IDGE), supported by NASA. Naturally such experiments are costly and one objective of the present investigation is to develop an experimental method whereby convection can be halted, in solidification and other experiments, on the Earth's surface. A second objective is to use the method to minimize convection resulting from the residual accelerations suffered by experiments in microgravity.

Use of Microgravity to Control the Microstructure of Eutectics

NASA Technical Reports Server (NTRS)

Wilcox. William R.; Regel, Liya L.

1999-01-01

This grant began in June of 1996. Its long term goal is to be able to control the microstructure of directionally solidified eutectic alloys, through an improved understanding of the influence of convection. The primary objective of the projects in the present grant is to test hypotheses for the reported influence of microgravity on the microstructure of eutectics. The prior experimental results on the influence of microgravity on the microstructure of eutectics have been contradictory. With lamellar eutectics, microgravity had a negligible effect on the microstructure. Microgravity experiments with fibrous eutectics sometimes showed a finer microstructure and sometimes a coarser microstructure. Most research has been done on the MnBi/Bi rod-like eutectic. Larson and Pirich obtained a two-fold finer microstructure both from microgravity and by use of a magnetic field to quench buoyancy-driven convection. Smith, on the other hand, observed no change in microgravity. Prior theoretical work at Clarkson University showed that buoyancy-driven convection in the vertical Bridgman configuration is not vigorous enough to alter the concentration field in front of a growing eutectic sufficiently to cause a measurable change in microstructure. We assumed that the bulk melt was at the eutectic composition and that freezing occurred at the extremum, i.e. with minimum total undercooling at the freezing interface. There have been four hypotheses attempting to explain the observed changes in microstructure of fibrous eutectics caused by convection: I .A fluctuating freezing rate, combined with unequal kinetics for fiber termination and branching. 2. Off-eutectic composition, either in the bulk melt due to an off-eutectic feed or at the freezing interface because of departure from the extremum condition. 3. Presence of a strong habit modifying impurity whose concentration at the freezing interface would be altered by convection. At the beginning of the present grant, we favored the first of these hypotheses and set out to test it both experimentally and theoretically. We planned the following approaches: I .Pass electric current pulses through the MnBi/Bi eutectic during directional solidification in order to produce an oscillatory freezing rate. 2. Directionally solidify the MnBi/Bi eutectic on Mir using the QUELD II gradient freeze furnace developed by Professor Smith at Queen's University. 3. Select another fibrous eutectic system for investigation using the Accelerated Crucible Rotation Technique to introduce convection. 4. Develop theoretical models for eutectic solidification with an oscillatory freezing rate. Because of the problems with Mir, we substituted ground-based experiments at Queen's University with QUELD II vertical and horizontal, with and without vibration of the furnace. The Al-Si system was chosen for the ACRT experiments. Three related approaches were used to model eutectic solidification with an oscillatory freezing rate. A sharp interface model was used to calculate composition oscillations at the freezing interface in response to imposed freezing rate oscillations.

Process modelling for materials preparation experiments

NASA Technical Reports Server (NTRS)

Rosenberger, Franz; Alexander, J. Iwan D.

1994-01-01

The main goals of the research under this grant consist of the development of mathematical tools and measurement techniques for transport properties necessary for high fidelity modelling of crystal growth from the melt and solution. Of the tasks described in detail in the original proposal, two remain to be worked on: development of a spectral code for moving boundary problems, and development of an expedient diffusivity measurement technique for concentrated and supersaturated solutions. We have focused on developing a code to solve for interface shape, heat and species transport during directional solidification. The work involved the computation of heat, mass and momentum transfer during Bridgman-Stockbarger solidification of compound semiconductors. Domain decomposition techniques and preconditioning methods were used in conjunction with Chebyshev spectral methods to accelerate convergence while retaining the high-order spectral accuracy. During the report period we have further improved our experimental setup. These improvements include: temperature control of the measurement cell to 0.1 C between 10 and 60 C; enclosure of the optical measurement path outside the ZYGO interferometer in a metal housing that is temperature controlled to the same temperature setting as the measurement cell; simultaneous dispensing and partial removal of the lower concentration (lighter) solution above the higher concentration (heavier) solution through independently motor-driven syringes; three-fold increase in data resolution by orientation of the interferometer with respect to diffusion direction; and increase of the optical path length in the solution cell to 12 mm.

Experimental observation of the influence of furnace temperature profile on convection and segregation in the vertical Bridgman crystal growth technique

NASA Technical Reports Server (NTRS)

Neugebauer, G. T.; Wilcox, William R.

1992-01-01

Azulene-doped naphthalene was directionally solidified during the vertical Bridgman-Stockbarger technique. Doping homogeneity and convection were determined as a function of the temperature profile in the furnace and the freezing rate. Convection velocities were two orders of magnitude lower when the temperature increased with height. Rarely was the convection pattern axisymmetric, even though the temperature varied less than 0.1 K around the circumference of the growth ampoule. Correspondingly the cross sectional variation in azulene concentration tended to be asymmetric, especially when the temperature increased with height. This cross sectional variation changed dramatically along the ingot, reflecting changes in convection presumably due to the decreasing height of the melt. Although there was large scatter and irreproducibility in the cross sectional variation in doping, this variation tended to be least when the growth rate was low and the convection was vigorous. It is expected that compositional variations would also be small at high growth rates with weak convection and flat interfaces, although this was not investigated in the present experiments. Neither rotation of the ampoule nor deliberate introduction of thermal asymmetries during solidification had a significant influence on cross sectional variations in doping. It is predicted that slow directional solidification under microgravity conditions could produce greater inhomogeneities than on Earth. Combined use of microgravity and magnetic fields would be required to achieve homogeneity when it is necessary to freeze slowly in order to avoid constitutional supercooling.

Solidification of eutectic system alloys in space (M-19)

NASA Technical Reports Server (NTRS)

Ohno, Atsumi

1993-01-01

It is well known that in the liquid state eutectic alloys are theoretically homogeneous under 1 g conditions. However, the homogeneous solidified structure of this alloy is not obtained because thermal convection and non-equilibrium solidification occur. The present investigators have clarified the solidification mechanisms of the eutectic system alloys under 1 g conditions by using the in situ observation method; in particular, the primary crystals of the eutectic system alloys never nucleated in the liquid, but instead did so on the mold wall, and the crystals separated from the mold wall by fluid motion caused by thermal convection. They also found that the equiaxed eutectic grains (eutectic cells) are formed on the primary crystals. In this case, the leading phase of the eutectic must agree with the phase of the primary crystals. In space, no thermal convection occurs so that primary crystals should not move from the mold wall and should not appear inside the solidified structure. Therefore no equiaxed eutectic grains will be formed under microgravity conditions. Past space experiments concerning eutectic alloys were classified into two types of experiments: one with respect to the solidification mechanisms of the eutectic alloys and the other to the unidirectional solidification of this alloy. The former type of experiment has the problem that the solidified structures between microgravity and 1 g conditions show little difference. This is why the flight samples were prepared by the ordinary cast techniques on Earth. Therefore it is impossible to ascertain whether or not the nucleation and growth of primary crystals in the melt occur and if primary crystals influence the formation of the equiaxed eutectic grains. In this experiment, hypo- and hyper-eutectic aluminum copper alloys which are near eutectic point are used. The chemical compositions of the samples are Al-32.4mass%Cu (Hypo-eutectic) and Al-33.5mass%Cu (hyper-eutectic). Long rods for the samples are cast by the Ohno Continuous Casting Process and they show the unidirectionally solidified structure. Each flight and ground sample was made of these same rods. The dimensions of all samples are 4.5 mm in diameter and 23.5 mm in length. Each sample is put in a graphite capsule and then vacuum sealed in a double silica ampoule. Then the ampoule is put in the tantalum cartridge and sealed by electron beam welding. For onbard experiments, a Continuous Heating Furnance (CHF) will be used for melting and solidifying samples under microgravity conditions. Six flight samples will be used. Four samples are hypo-eutectic and two are hyper-eutectic alloys. The surface of the two hypo-eutectic alloy samples are covered with aluminum oxide film to prevent Marangoni convection expected under microgravity conditions. Each sample will be heated to 700 C and held at that temperature for 5 min. After that the samples will be allowed to cool to 500 C in the furnace and they will be taken out of the furnace for He gas cooling. The heating and cooling diagrams for the flight experiments are shown. After collecting the flight samples, the solidified structures of the samples will be examined and the mechanisms of eutectic solidification under microgravity conditions will be determined. It is likely that successful flight experiment results will lead to production of high quality eutectic alloys and eutectic composite materials in space.

Analysis of X-Ray Microradiographs of Al-Au Interface Quench Profile using Modeling of Solidification Including Double-Diffusion and Convection in the Melt

NASA Technical Reports Server (NTRS)

Bune, Andris V.; Kaukler, William

1999-01-01

Experimental data on Al-0.8Au horizontal solidification of a 1 mm thick specimen in a BN crucible shows the effect of growth rate on the solidification interface shape. For translation rates below 0.5 micron/s the interface maintains a plain and flat shape. When the translation rate is 3 to 5 micron/s or more, the interface appearance changes to two planar zones, with the zone closer to the bottom having higher inclination. The interface shapes were measured by first quenching in place during growth. X-ray microscopy shows the interface shape within the quenched sample by viewing through the side of the specimen. In order to provide theoretical explanation of the phenomena, numerical modeling was undertaken using finite element code FIDAP. Double diffusion convection in Al-0.8Au melt and crystal-melt interface curvature during directional solidification was analyzed numerically. Actual thermophysical properties of Al-0.8Au including the binary Al-Au phase diagram were used. Although convection in the sample is weak, for the slower translation rate convection and diffusion is sufficient for the redistribution of initial compositional stratification caused by gravity. When translation rate is raised, neither convection nor diffusion can provide proper mixing so that solidification temperatures differ significantly near the bottom within the bulk of the sample. As a result, the solid-liquid interface appears to have two planar zones with different inclination.

Using Snow to Teach Geology.

ERIC Educational Resources Information Center

Roth, Charles

1991-01-01

A lesson plan, directed at middle school students and older, describes using snow to study the geological processes of solidification of molten material, sedimentation, and metamorphosis. Provides background information on these geological processes. (MCO)

Heat transfer analytical models for the rapid determination of cooling time in crystalline thermoplastic injection molding and experimental validation

NASA Astrophysics Data System (ADS)

Didier, Delaunay; Baptiste, Pignon; Nicolas, Boyard; Vincent, Sobotka

2018-05-01

Heat transfer during the cooling of a thermoplastic injected part directly affects the solidification of the polymer and consequently the quality of the part in term of mechanical properties, geometric tolerance and surface aspect. This paper proposes to mold designers a methodology based on analytical models to provide quickly the time to reach the ejection temperature depending of the temperature and the position of cooling channels. The obtained cooling time is the first step of the thermal conception of the mold. The presented methodology is dedicated to the determination of solidification time of a semi-crystalline polymer slab. It allows the calculation of the crystallization time of the part and is based on the analytical solution of the Stefan problem in a semi-infinite medium. The crystallization is then considered as a phase change with an effective crystallization temperature, which is obtained from Fast Scanning Calorimetry (FSC) results. The crystallization time is then corrected to take the finite thickness of the part into account. To check the accuracy of such approach, the solidification time is calculated by solving the heat conduction equation coupled to the crystallization kinetics of the polymer. The impact of the nature of the contact between the polymer and the mold is evaluated. The thermal contact resistance (TCR) appears as significant parameter that needs to be taken into account in the cooling time calculation. The results of the simplified model including or not TCR are compared in the case of a polypropylene (PP) with experiments carried out with an instrumented mold. Then, the methodology is applied for a part made with PolyEtherEtherKetone (PEEK).

Formation of Hot Tear Under Controlled Solidification Conditions

NASA Astrophysics Data System (ADS)

Subroto, Tungky; Miroux, Alexis; Bouffier, Lionel; Josserond, Charles; Salvo, Luc; Suéry, Michel; Eskin, Dmitry G.; Katgerman, Laurens

2014-06-01

Aluminum alloy 7050 is known for its superior mechanical properties, and thus finds its application in aerospace industry. Vertical direct-chill (DC) casting process is typically employed for producing such an alloy. Despite its advantages, AA7050 is considered as a "hard-to-cast" alloy because of its propensity to cold cracking. This type of cracks occurs catastrophically and is difficult to predict. Previous research suggested that such a crack could be initiated by undeveloped hot tears (microscopic hot tear) formed during the DC casting process if they reach a certain critical size. However, validation of such a hypothesis has not been done yet. Therefore, a method to produce a hot tear with a controlled size is needed as part of the verification studies. In the current study, we demonstrate a method that has a potential to control the size of the created hot tear in a small-scale solidification process. We found that by changing two variables, cooling rate and displacement compensation rate, the size of the hot tear during solidification can be modified in a controlled way. An X-ray microtomography characterization technique is utilized to quantify the created hot tear. We suggest that feeding and strain rate during DC casting are more important compared with the exerted force on the sample for the formation of a hot tear. In addition, we show that there are four different domains of hot-tear development in the explored experimental window—compression, microscopic hot tear, macroscopic hot tear, and failure. The samples produced in the current study will be used for subsequent experiments that simulate cold-cracking conditions to confirm the earlier proposed model.

A Review of Permanent Magnet Stirring During Metal Solidification

NASA Astrophysics Data System (ADS)

Zeng, Jie; Chen, Weiqing; Yang, Yindong; Mclean, Alexander

2017-12-01

Rather than using conventional electromagnetic stirring (EMS) with three-phase alternating current, permanent magnet stirring (PMS), based on the use of sintered NdFeB material which has excellent magnetic characteristics, can be employed to generate a magnetic field for the stirring of liquid metal during solidification. Recent experience with steel casting indicates that PMS requires less than 20 pct of the total energy compared with EMS. Despite the excellent magnetic density properties and low power consumption, this relatively new technology has received comparatively little attention by the metal casting community. This paper reviews simulation modeling, experimental studies, and industrial trials of PMS conducted during recent years. With the development of magnetic simulation software, the magnetic field and associated flow patterns generated by PMS have been evaluated. Based on the results obtained from laboratory experiments, the effects of PMS on metal solidification structures and typical defects such as surface pinholes and center cavities are summarized. The significance of findings obtained from trials of PMS within the metals processing sector, including the continuous casting of steel, are discussed with the aim of providing an overview of the relevant parameters that are of importance for further development and industrial application of this innovative technology.

Investigation on the solidification course of Al-Si alloys by using a numerical Newtonian thermal analysis method

NASA Astrophysics Data System (ADS)

Tang, Peng; Hu, Zhiliu; Zhao, Yanjun; Huang, Qingbao

2017-12-01

A numerical Newtonian thermal analysis (NTA) method was carried out for online monitoring the solidification course of commercial Al-Si alloys. The solidification paths of different molten Al-Si alloys were characterized by the fraction solid curves. The variation of heat capacity of Al and Si were concerned in the determination of baseline evaluation of latent heat. In this experiment, the pure Al, Al-1Si, Al-5Si, Al-9Si, Al-13Si and Al-18Si alloys were molten at 800 °C and cooled at room temperature, respectively. The cooling curves of these alloys were measured by using K-type thermocouples. The liquidus temperatures of these alloys decreased with the increase of Si %. An obvious stage occurred at about 580 °C, which was closely related to Al-Si eutectic reaction. Different phase fractions of these alloys were supported by the microstructure observation.

Experiments with the low melting indium-bismuth alloy system

NASA Technical Reports Server (NTRS)

Krepski, Richard P.

1992-01-01

The following is a laboratory experiment designed to create an interest in and to further understanding of materials science. The primary audience for this material is the junior high school or middle school science student having no previous familiarity with the material, other than some knowledge of temperature and the concepts of atoms, elements, compounds, and chemical reactions. The objective of the experiment is to investigate the indium-bismuth alloy system. Near the eutectic composition, the liquidus is well below the boiling point of water, allowing simple, minimal hazard casting experiments. Such phenomena as metal oxidation, formation of intermetallic compound crystals, and an unusual volume increase during solidification could all be directly observed. A key concept for students to absorb is that properties of an alloy (melting point, mechanical behavior) may not correlate with simple interpolation of properties of the pure components. Discussion of other low melting metals and alloys leads to consideration of environmental and toxicity issues, as well as providing some historical context. Wetting behavior can also be explored.

Grain Floatation During Equiaxed Solidification of an Al-Cu Alloy in a Side-Cooled Cavity: Part II—Numerical Studies

NASA Astrophysics Data System (ADS)

Kumar, Arvind; Walker, Mike J.; Sundarraj, Suresh; Dutta, Pradip

2011-08-01

In this article, a single-phase, one-domain macroscopic model is developed for studying binary alloy solidification with moving equiaxed solid phase, along with the associated transport phenomena. In this model, issues such as thermosolutal convection, motion of solid phase relative to liquid and viscosity variations of the solid-liquid mixture with solid fraction in the mobile zone are taken into account. Using the model, the associated transport phenomena during solidification of Al-Cu alloys in a rectangular cavity are predicted. The results for temperature variation, segregation patterns, and eutectic fraction distribution are compared with data from in-house experiments. The model predictions compare well with the experimental results. To highlight the influence of solid phase movement on convection and final macrosegregation, the results of the current model are also compared with those obtained from the conventional solidification model with stationary solid phase. By including the independent movement of the solid phase into the fluid transport model, better predictions of macrosegregation, microstructure, and even shrinkage locations were obtained. Mechanical property prediction models based on microstructure will benefit from the improved accuracy of this model.

Containerless drop tube solidification and grain refinement of NiAl3

NASA Technical Reports Server (NTRS)

Ethridge, E. C.; Curreri, P. A.; Kelly, M.; Workman, G.; Smith, A. M.; Bond, R.

1984-01-01

The possibility of undercooling Ni-Al alloys below the liquidus in order to produce a single phase peritectic structure by containerless drop tube solidification was studied. Containerless process is a technique for both high purity contamination free studies as well as for investigating the undercooling and rapid solidification of alloys by suppression of heterogeneous nucleation on container walls. In order to achieve large undercoolings one must avoid heterogeneous nucleation of crystallization. It was shown that the Marshall Space Flight Center drop tubes ae unique facilities for containerless solidification experiments and large undercoolings are possible with some alloys. The original goal of undercooling the liquid metal well below the liquidus to the peritectic temperature during containerless free to form primarily NiAl3 was achieved. The microstructures were interesting from another point of view. The microstructure from small diameter samples is greatly refined. Small dendrite arm spacings such as these could greatly facilitate the annealing and solid state transformation of the alloy to nearly 10% NiAl3 by reducing the distance over which diffusion needs to occur. This could minimize annealing time and might make it economically feasible to produce NiAl3 alloy.

Metastable solidification of hypereutectic Co 2Si-CoSi composition: Microstructural studies and in-situ observations

DOE PAGES

Wang, Yeqing; Gao, Jianrong; Kolbe, Matthias; ...

2017-09-18

Metastable solidification of undercooled Co 60Si 40 melts was investigated by microstructural studies and in-situ high-energy X-ray diffraction. Five solidification paths were identified. Three of them were observed at low undercoolings, which show uncoupled and coupled growth of stable β-Co 2Si and CoSi compounds. The other paths were observed at high undercoolings, which show peritectic and primary crystallization of a metastable Co 5Si 3 compound. The β-Co 2Si and Co 5Si 3 compounds crystallize into a hexagonal crystal structure and experience solid-state decomposition. Microstructure formation depends on solidification path. The coupled and uncoupled growth of the stable compounds produces amore » regular lamellar eutectic structure and an anomalous eutectic structure, respectively. The crystallization and solid-state decomposition of the metastable Co 5Si 3 compound brings about a fine-grained two-phase mixture, which represents another type of anomalous eutectic structure. Here, the results provide proof of two rare mechanisms of anomalous eutectic formation and shed light onto metastable phase relations in the undercooled region of the Co-Si system.« less

Progress on Numerical Modeling of the Dispersion of Ceramic Nanoparticles During Ultrasonic Processing and Solidification of Al-Based Nanocomposites

NASA Astrophysics Data System (ADS)

Zhang, Daojie; Nastac, Laurentiu

2016-12-01

In present study, 6061- and A356-based nano-composites are fabricated by using the ultrasonic stirring technology (UST) in a coreless induction furnace. SiC nanoparticles are used as the reinforcement. Nanoparticles are added into the molten metal and then dispersed by ultrasonic cavitation and acoustic streaming assisted by electromagnetic stirring. The applied UST parameters in the current experiments are used to validate a recently developed magneto-hydro-dynamics (MHD) model, which is capable of modeling the cavitation and nanoparticle dispersion during UST processing. The MHD model accounts for turbulent fluid flow, heat transfer and solidification, and electromagnetic field, as well as the complex interaction between the nanoparticles and both the molten and solidified alloys by using ANSYS Maxwell and ANSYS Fluent. Molecular dynamics (MD) simulations are conducted to analyze the complex interactions between the nanoparticle and the liquid/solid interface. The current modeling results demonstrate that a strong flow can disperse the nanoparticles relatively well during molten metal and solidification processes. MD simulation results prove that ultrafine particles (10 nm) will be engulfed by the solidification front instead of being pushed, which is beneficial for nano-dispersion.

Metastable solidification of hypereutectic Co 2Si-CoSi composition: Microstructural studies and in-situ observations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Yeqing; Gao, Jianrong; Kolbe, Matthias

Metastable solidification of undercooled Co 60Si 40 melts was investigated by microstructural studies and in-situ high-energy X-ray diffraction. Five solidification paths were identified. Three of them were observed at low undercoolings, which show uncoupled and coupled growth of stable β-Co 2Si and CoSi compounds. The other paths were observed at high undercoolings, which show peritectic and primary crystallization of a metastable Co 5Si 3 compound. The β-Co 2Si and Co 5Si 3 compounds crystallize into a hexagonal crystal structure and experience solid-state decomposition. Microstructure formation depends on solidification path. The coupled and uncoupled growth of the stable compounds produces amore » regular lamellar eutectic structure and an anomalous eutectic structure, respectively. The crystallization and solid-state decomposition of the metastable Co 5Si 3 compound brings about a fine-grained two-phase mixture, which represents another type of anomalous eutectic structure. Here, the results provide proof of two rare mechanisms of anomalous eutectic formation and shed light onto metastable phase relations in the undercooled region of the Co-Si system.« less

Directional solidification of silicon in carbon crucibles by an oscillating crucible technique

NASA Technical Reports Server (NTRS)

Daud, T.; Dumas, K. A.; Schwuttke, G. H.; Smetana, P.; Kim, K. M.

1982-01-01

The quality of silicon cast by present techniques is limited by the presence of dislocations and grain boundaries in unseeded growth and by cellular structures with dislocation networks in the case of the seeded growth. To address these concerns, a new method of directional solidification called the oscillating crucible technique (OCT) is developed. During growth, a carbon crucible is oscillated to provide for effective stirring of the melt. This growth technique (seeded growth only), along with material characterization and solar-cell fabrication and testing, is described. Solar-cell efficiencies of up to 13 percent at 100 mW/sq cm area obtained in the single crystalline areas. Minority-carrier diffusion lengths exceeding 100 microns are measured even in the polycrystalline areas of the wafers. Limitations of the present setup and possible future improvements are discussed.

Experimental observation of the influence of furnace temperature profile on convection and segregation in the vertical Bridgman crystal growth technique

NASA Technical Reports Server (NTRS)

Neugebauer, G. T.; Wilcox, W. R.

1990-01-01

Azulene-doped naphtalene was directionally solidified using the vertical Bridgman-Stockbarger technique. Doping homogeneity and convection are determined as a function of the temperature profile in the furnace and the freezing rate. Convective velocities are two orders of magnitude lower when the temperature increases with height. The cross sectional variation in azulene concentration tends to be asymmetric. Neither rotation of the ampoule nor deliberate introduction of thermal asymmetries during solidification had a significant influence on cross sectional variations in doping. It is predicted that slow directional solidification under microgravity conditions can produce greater inhomogeneities than on earth. Thus when low freezing rates are necessary in order to avoid constitutional supercooling, it may be necessary to combine microgravity and magnetic fields in order to achieve homogeneous crystals.

Modeling transport phenomena and uncertainty quantification in solidification processes

NASA Astrophysics Data System (ADS)

Fezi, Kyle S.

Direct chill (DC) casting is the primary processing route for wrought aluminum alloys. This semicontinuous process consists of primary cooling as the metal is pulled through a water cooled mold followed by secondary cooling with a water jet spray and free falling water. To gain insight into this complex solidification process, a fully transient model of DC casting was developed to predict the transport phenomena of aluminum alloys for various conditions. This model is capable of solving mixture mass, momentum, energy, and species conservation equations during multicomponent solidification. Various DC casting process parameters were examined for their effect on transport phenomena predictions in an alloy of commercial interest (aluminum alloy 7050). The practice of placing a wiper to divert cooling water from the ingot surface was studied and the results showed that placement closer to the mold causes remelting at the surface and increases susceptibility to bleed outs. Numerical models of metal alloy solidification, like the one previously mentioned, are used to gain insight into physical phenomena that cannot be observed experimentally. However, uncertainty in model inputs cause uncertainty in results and those insights. The analysis of model assumptions and probable input variability on the level of uncertainty in model predictions has not been calculated in solidification modeling as yet. As a step towards understanding the effect of uncertain inputs on solidification modeling, uncertainty quantification (UQ) and sensitivity analysis were first performed on a transient solidification model of a simple binary alloy (Al-4.5wt.%Cu) in a rectangular cavity with both columnar and equiaxed solid growth models. This analysis was followed by quantifying the uncertainty in predictions from the recently developed transient DC casting model. The PRISM Uncertainty Quantification (PUQ) framework quantified the uncertainty and sensitivity in macrosegregation, solidification time, and sump profile predictions. Uncertain model inputs of interest included the secondary dendrite arm spacing, equiaxed particle size, equiaxed packing fraction, heat transfer coefficient, and material properties. The most influential input parameters for predicting the macrosegregation level were the dendrite arm spacing, which also strongly depended on the choice of mushy zone permeability model, and the equiaxed packing fraction. Additionally, the degree of uncertainty required to produce accurate predictions depended on the output of interest from the model.

Detachment of secondary dendrite arm in a directionally solidified Sn-Ni peritectic alloy under deceleration growth condition

PubMed Central

Peng, Peng; Li, Xinzhong; Li, Jiangong; Su, Yanqing; Guo, Jingjie; Fu, Hengzhi

2016-01-01

In order to better understand the detachment mechanism of secondary dendrite arm during peritectic solidification, the detachment of secondary dendrite arm from the primary dendrite arms in directionally solidified Sn-36at.%Ni peritectic alloys is investigated at different deceleration rates. Extensive detachment of secondary dendrite arms from primary stem is observed below peritectic reaction temperature TP. And an analytical model is established to characterize the detachment process in terms of the secondary dendrite arm spacing λ2, the root radius of detached arms and the specific surface area (SV) of dendrites. It is found that the detachment mechanism is caused by not only curvature difference between the tips and roots of secondary branches, but also that between the thicker secondary branches and the thinner ones. Besides, this detachment process is significantly accelerated by the temperature gradient zone melting (TGZM) effect during peritectic solidification. It is demonstrated that the reaction constant (f) which is used to characterize the kinetics of peritectic reaction is crucial for the determination of the detachment process. The value of f not only changes with growth rate but also with solidification time at a given deceleration rate. In conclusion, these findings help the better understanding of the detachment mechanism. PMID:27270334

Experiments on Nucleation in Different Flow Regimes

NASA Technical Reports Server (NTRS)

Bayuzick, R. J.; Hofmeister, W. H.; Morton, C. M.; Robinson, M. B.

1998-01-01

The vast majority of metallic engineering materials are solidified from the liquid phase. Understanding the solidification process is essential to control microstructure, which in turn, determines the properties of materials. The genesis of solidification is nucleation, where the first stable solid forms from the liquid phase. Nucleation kinetics determine the degree of undercooling and phase selection. As such, it is important to understand nucleation phenomena in order to control solidification or glass formation in metals and alloys. Early experiments in nucleation kinetics were accomplished by droplet dispersion methods. Dilitometry was used by Turnbull and others, and more recently differential thermal analysis and differential scanning calorimetry have been used for kinetic studies. These techniques have enjoyed success; however, there are difficulties with these experiments. Since materials are dispersed in a medium, the character of the emulsion/metal interface affects the nucleation behavior. Statistics are derived from the large number of particles observed in a single experiment, but dispersions have a finite size distribution which adds to the uncertainty of the kinetic determinations. Even though temperature can be controlled quite well before the onset of nucleation, the release of the latent heat of fusion during nucleation of particles complicates the assumption of isothermality during these experiments. Containerless processing has enabled another approach to the study of nucleation kinetics. With levitation techniques it is possible to undercool one sample to nucleation repeatedly in a controlled manner, such that the statistics of the nucleation process can be derived from multiple experiments on a single sample. The authors have fully developed the analysis of nucleation experiments on single samples following the suggestions of Skripov. The advantage of these experiments is that the samples are directly observable. The nucleation temperature can be measured by noncontact optical pyrometry, the mass of the sample is known, and post-processing analysis can be conducted on the sample. The disadvantages are that temperature measurement must have exceptionally high precision, and it is not possible to isolate specific heterogeneous sites as in droplet dispersions. Levitation processing of refractory materials in ultra high vacuum provides an avenue to conduct these kinetic studies on single samples. Two experimental methods have been identified where ultra high vacuum experiments are possible; electrostatic levitation in ground-based experiments and electromagnetic processing in low earth orbit on TEMPUS. Such experiments, reported here, were conducted on zirconium. Liquid zirconium is an excellent solvent and has a high solubility for contaminants contained in the bulk material as well as those contaminants found in the vacuum environment. Oxides, nitrides, and carbides do not exist in the melt, and do not form on the surface of molten zirconium, for the materials and vacuum levels used in this study. Ground-based experiments with electrostatic levitation have shown that the statistical nucleation kinetic experiments are viable and yield results which are consistent with classical nucleation theory. The advantage of low earth orbit experiments is the ability to vary the flow conditions in the liquid prior to nucleation. The put-pose of nucleation experiments in TEMPUS was to examine.

Study of Magnetic Damping Effect on Convection and Solidification Under G-Jitter Conditions

NASA Technical Reports Server (NTRS)

Li, Ben Q.; deGroh, H. C.

2001-01-01

As shown in space flight experiments, g-jitter is a critical issue affecting solidification processing of materials in microgravity. This study aims to provide, through extensive numerical simulations and ground based experiments, an assessment of the use of magnetic fields in combination with microgravity to reduce the g-jitter induced convective flows in space processing systems. Analytical solutions and 2-D and 3-D numerical models for g-jitter driven flows in simple solidification systems with and without the presence of an applied magnetic field have been developed and extensive analyses were carried out. A physical model was also constructed and PIV measurements compared reasonably well with predictions from numerical models. Some key points may be summarized as follows: (1) the amplitude of the oscillating velocity decreases at a rate inversely proportional to the g-jitter frequency and with an increase in the applied magnetic field; (2) the induced flow oscillates at approximately the same frequency as the affecting g-jitter, but out of a phase angle; (3) the phase angle is a complicated function of geometry, applied magnetic field, temperature gradient and frequency; (4) g-jitter driven flows exhibit a complex fluid flow pattern evolving in time; (5) the damping effect is more effective for low frequency flows; and (6) the applied magnetic field helps to reduce the variation of solutal distribution along the solid-liquid interface. Work in progress includes developing numerical models for solidification phenomena with the presence of both g-jitter and magnetic fields and developing a ground-based physical model to verify numerical predictions.

The Fractional Step Method Applied to Simulations of Natural Convective Flows

NASA Technical Reports Server (NTRS)

Westra, Douglas G.; Heinrich, Juan C.; Saxon, Jeff (Technical Monitor)

2002-01-01

This paper describes research done to apply the Fractional Step Method to finite-element simulations of natural convective flows in pure liquids, permeable media, and in a directionally solidified metal alloy casting. The Fractional Step Method has been applied commonly to high Reynold's number flow simulations, but is less common for low Reynold's number flows, such as natural convection in liquids and in permeable media. The Fractional Step Method offers increased speed and reduced memory requirements by allowing non-coupled solution of the pressure and the velocity components. The Fractional Step Method has particular benefits for predicting flows in a directionally solidified alloy, since other methods presently employed are not very efficient. Previously, the most suitable method for predicting flows in a directionally solidified binary alloy was the penalty method. The penalty method requires direct matrix solvers, due to the penalty term. The Fractional Step Method allows iterative solution of the finite element stiffness matrices, thereby allowing more efficient solution of the matrices. The Fractional Step Method also lends itself to parallel processing, since the velocity component stiffness matrices can be built and solved independently of each other. The finite-element simulations of a directionally solidified casting are used to predict macrosegregation in directionally solidified castings. In particular, the finite-element simulations predict the existence of 'channels' within the processing mushy zone and subsequently 'freckles' within the fully processed solid, which are known to result from macrosegregation, or what is often referred to as thermo-solutal convection. These freckles cause material property non-uniformities in directionally solidified castings; therefore many of these castings are scrapped. The phenomenon of natural convection in an alloy under-going directional solidification, or thermo-solutal convection, will be explained. The development of the momentum and continuity equations for natural convection in a fluid, a permeable medium, and in a binary alloy undergoing directional solidification will be presented. Finally, results for natural convection in a pure liquid, natural convection in a medium with a constant permeability, and for directional solidification will be presented.

Mechanism of competitive grain growth in a curvilinear channel of crystal-sorter during the orientational solidification of nickel-based heat-resistant alloy

NASA Astrophysics Data System (ADS)

Monastyrskiy, V. P.; Pozdnyakov, A. N.; Ershov, M. Yu.; Monastyrskiy, A. V.

2017-07-01

Using numerical simulation in the ProCAST program complex, the conditions of the solidification of heat-resistant nickel alloy in curvilinear channels of a ceramic mold have been investigated. It has been shown that, in practically important cases, the vector of the temperature gradient is oriented along the axis of the curvilinear channel. In a spiral crystal selector, a cyclic change in the preferred direction of growth occurs because of the cyclic change in the direction of the vector of the temperature gradient. The fact that the vector of the temperature gradient is almost always directed along the axis of the curvilinear channel makes it possible to govern the orientation of the vector of the temperature gradient in space and, therefore, to obtain a grain with the preferred crystallographic orientation. Based on the results of this investigation, a method of the grain selection with a desired azimuthal orientation is proposed.

Partial melting of a Pb-Sn mushy layer due to heating from above, and implications for regional melting of Earth's directionally solidified inner core

NASA Astrophysics Data System (ADS)

Yu, James; Bergman, Michael I.; Huguet, Ludovic; Alboussiere, Thierry

2015-09-01

Superimposed on the radial solidification of Earth's inner core may be hemispherical and/or regional patches of melting at the inner-outer core boundary. Little work has been carried out on partial melting of a dendritic mushy layer due to heating from above. Here we study directional solidification, annealing, and partial melting from above of Pb-rich Sn alloy ingots. We find that partial melting from above results in convection in the mushy layer, with dense, melted Pb sinking and resolidifying at a lower height, yielding a different density profile than for those ingots that are just directionally solidified, irrespective of annealing. Partial melting from above causes a greater density deeper down and a corresponding steeper density decrease nearer the top. There is also a change in microstructure. These observations may be in accordance with inferences of east-west and perhaps smaller-scale variations in seismic properties near the top of the inner core.

Texturing of high T(sub c) superconducting polycrystalline fibers/wires by laser-driven directional solidification in an thermal gradient

NASA Technical Reports Server (NTRS)

Varshney, Usha; Eichelberger, B. Davis, III

1995-01-01

This paper summarizes the technique of laser-driven directional solidification in a controlled thermal gradient of yttria stabilized zirconia core coated Y-Ba-Cu-O materials to produce textured high T(sub c) superconducting polycrystalline fibers/wires with improved critical current densities in the extended range of magnetic fields at temperatures greater than 77 K. The approach involves laser heating to minimize phase segregation by heating very rapidly through the two-phase incongruent melt region to the single phase melt region and directionally solidifying in a controlled thermal gradient to achieve highly textured grains in the fiber axis direction. The technique offers a higher grain growth rate and a lower thermal budget compared with a conventional thermal gradient and is amenable as a continuous process for improving the J(sub c) of high T(sub c) superconducting polycrystalline fibers/wires. The technique has the advantage of suppressing weak-link behavior by orientation of crystals, formation of dense structures with enhanced connectivity, formation of fewer and cleaner grain boundaries, and minimization of phase segregation in the incongruent melt region.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Choi, Jeong

The research program reported here is focused on critical issues that represent conspicuous gaps in current understanding of rapid solidification, limiting our ability to predict and control microstructural evolution (i.e. morphological dynamics and microsegregation) at high undercooling, where conditions depart significantly from local equilibrium. More specifically, through careful application of phase-field modeling, using appropriate thin-interface and anti-trapping corrections and addressing important details such as transient effects and a velocity-dependent (i.e. adaptive) numerics, the current analysis provides a reasonable simulation-based picture of non-equilibrium solute partitioning and the corresponding oscillatory dynamics associated with single-phase rapid solidification and show that this method ismore » a suitable means for a self-consistent simulation of transient behavior and operating point selection under rapid growth conditions. Moving beyond the limitations of conventional theoretical/analytical treatments of non-equilibrium solute partitioning, these results serve to substantiate recent experimental findings and analytical treatments for single-phase rapid solidification. The departure from the equilibrium solid concentration at the solid-liquid interface was often observed during rapid solidification, and the energetic associated non-equilibrium solute partitioning has been treated in detail, providing possible ranges of interface concentrations for a given growth condition. Use of these treatments for analytical description of specific single-phase dendritic and cellular operating point selection, however, requires a model for solute partitioning under a given set of growth conditions. Therefore, analytical solute trapping models which describe the chemical partitioning as a function of steady state interface velocities have been developed and widely utilized in most of the theoretical investigations of rapid solidification. However, these solute trapping models are not rigorously verified due to the difficulty in experimentally measuring under rapid growth conditions. Moreover, since these solute trapping models include kinetic parameters which are difficult to directly measure from experiments, application of the solute trapping models or the associated analytic rapid solidification model is limited. These theoretical models for steady state rapid solidification which incorporate the solute trapping models do not describe the interdependency of solute diffusion, interface kinetics, and alloy thermodynamics. The phase-field approach allows calculating, spontaneously, the non-equilibrium growth effects of alloys and the associated time-dependent growth dynamics, without making the assumptions that solute partitioning is an explicit function of velocity, as is the current convention. In the research described here, by utilizing the phase-field model in the thin-interface limit, incorporating the anti-trapping current term, more quantitatively valid interface kinetics and solute diffusion across the interface are calculated. In order to sufficiently resolve the physical length scales (i.e. interface thickness and diffusion boundary length), grid spacings are continually adjusted in calculations. The full trajectories of transient planar growth dynamics under rapid directional solidification conditions with different pulling velocities are described. As a validation of a model, the predicted steady state conditions are consistent with the analytic approach for rapid growth. It was confirmed that rapid interface dynamics exhibits the abrupt acceleration of the planar front when the effect of the non-equilibrium solute partitioning at the interface becomes signi ficant. This is consistent with the previous linear stability analysis for the non-equilibrium interface dynamics. With an appropriate growth condition, the continuous oscillation dynamics was able to be simulated using continually adjusting grid spacings. This oscillatory dynamics including instantaneous jump of interface velocities are consistent with a previous phenomenological model by and a numerical investigation, which may cause the formation of banded structures. Additionally, the selection of the steady state growth dynamics in the highly undercooled melt is demonstrated. The transition of the growth morphology, interface velocity selection, and solute trapping phenomenon with increasing melt supersaturations was described by the phase-field simulation. The tip selection for the dendritic growth was consistent with Ivantsov's function, and the non-equilibrium chemical partitioning behavior shows good qualitative agreement with the Aziz's solute trapping model even though the model parameter(V D) remains as an arbitrary constant. This work is able to show the possibility of comprehensive description of rapid alloy growth over the entire time-dependent non-equilibrium phenomenon.« less

Crucible de-wetting during bridgman growth of semiconductors in microgravity

NASA Astrophysics Data System (ADS)

Duffar, T.; Paret-Harter, I.; Dusserre, P.

1990-02-01

After a literature survey and observations made during a space experiment, the phenomenon of crucible de-wetting by the crystal during Bridgman solidification in microgravity is explained by a model involving composite wetting of the crucible by the liquid, crystal angle of growth and interface advance. A ground experiment was run in order to validate this model which also explains why a crystal detaches from the crucible surface when a sand blasted crucible is used in Bridgman solidification on the ground. It is shown that de-wetting leads to enhanced quality of the crystal produced and that capillary-induced convection effects are not to be feared in this case. Consequently, it is highly advisable to use rough-surface crucibles for crystal growth both in microgravity and on the ground.

Control of ingot quality and solar cell appearance of cast mono-like silicon by using seed partitions

NASA Astrophysics Data System (ADS)

Lan, C. Y.; Wu, Y. C.; Lan, A.; Yang, C. F.; Hsu, C.; Lu, C. M.; Yang, A.; Lan, C. W.

2017-10-01

The growth of mono-like ingot by directional solidification has suffered serious problems in defect control. We proposed a simple approach by using seed partitions, and the grown crystal had much lower defects and better orientation uniformity. Furthermore, the partitions allowed the much easier seed preparation, which had a significant advantage in production. The concept was demonstrated by a G1 experiment, and the detailed defect analyses were carried out. The wafers after gettering had the best lifetime of more than 1 ms after surface passivation. The color mismatch in the appearance of the solar cells made from the wafer was also significantly mitigated.

Preparation for microgravity - The role of the Microgravity Material Science Laboratory

NASA Technical Reports Server (NTRS)

Johnston, J. Christopher; Rosenthal, Bruce N.; Meyer, Maryjo B.; Glasgow, Thomas K.

1988-01-01

Experiments at the NASA Lewis Research Center's Microgravity Material Science Laboratory using physical and mathematical models to delineate the effects of gravity on processes of scientific and commercial interest are discussed. Where possible, transparent model systems are used to visually track convection, settling, crystal growth, phase separation, agglomeration, vapor transport, diffusive flow, and polymer reactions. Materials studied include metals, alloys, salts, glasses, ceramics, and polymers. Specific technologies discussed include the General Purpose furnace used in the study of metals and crystal growth, the isothermal dendrite growth apparatus, the electromagnetic levitator/instrumented drop tube, the high temperature directional solidification furnace, the ceramics and polymer laboratories and the center's computing facilities.

The Isothermal Dendritic Growth Experiment

NASA Technical Reports Server (NTRS)

Glicksman, M. E.; Koss, M. B.; Malarik, D. C.

1998-01-01

The growth of dendrites is one of the commonly observed forms of solidification encountered when metals and alloys freeze under low thermal gradients, as occurs in most casting and welding processes. In engineering alloys, the details of the dendritic morphology directly relates to important material responses and properties. Of more generic interest, dendritic growth is also an archetypical problem in morphogenesis, where a complex pattern evolves from simple starting conditions. Thus, the physical understanding and mathematical description of how dendritic patterns emerge during the growth process are of interest to both scientists and engineers. The Isothermal Dendritic Growth Experiment (IDGE) is a basic science experiment designed to measure, for a fundamental test of theory, the kinetics and morphology of dendritic growth without complications induced by gravity-driven convection. The IDGE, a collaboration between Rensselaer Polytechnic Institute, in Troy NY, and NASA's Lewis Research Center (LeRC) was developed over a ten year period from a ground-based research program into a space flight experiment. Important to the success of this flight experiment was provision of in situ near-real-time teleoperations during the spaceflight experiment.

Optimization to Develop Multiple Response Microstructure and Hardness of Ductile Iron Casting by using GRA

NASA Astrophysics Data System (ADS)

Kabnure, Bahubali Bhupal; Shinde, Vasudev Dhondiram; Kolhapure, Rakesh Ramchandra

2018-05-01

Ductile irons are important engineering materials because of its high strength to weight ratio and castability. The ductile iron castings are used widely for automobile applications due to their wide spectrum of property range. Weight reduction is important in automobile to improve its fuel efficiency which can be achieved by thinning down the casting sections without altering its functionality. Generally, automobile castings are having varying section thickness. Varying thickness castings offers different cooling rates while solidification of the casting. The solidification cooling rate decides the final microstructure of the cast components. Cooling rate was found to affect directly the amount of pearlite and ultimately the as cast properties in varying thickness ductile iron castings. In view of this, the automobile impeller casting is selected for study in the present work as it consists of varying section thickness in which small sections are connected to central hub. The casting solidification simulations were performed and analyzed. The solidification cooling rates were analyzed further to correlate the experimental processing parameters. The samples from poured castings were analyzed for microstructure and hardness at different section thickness. Multiple response optimization of microstructure and hardness was carried out by combined Taguchi and Grey Relational Analysis (GRA). Contribution of input variables on the output variables is attained using ANOVA.

Numerical Analysis of Temperature Gradients and Interface Shape During Directional Solidification of Al and Al-Cu Alloy Under Microgravity Conditions

NASA Technical Reports Server (NTRS)

Bune, Andris V.; Sen, Subhayu; Mukherjee, Sundeep; Catalina, Adrian; Stefanescu, Doru M.

1999-01-01

Numerical modeling was undertaken to analyze the influence of radial thermal gradient on solid/liquid (s/1) interface shape and convection patterns during solidification of pure Al and Al-4 wt% Cu alloy. The objective of the numerical task was to predict the influence of convective velocity on an insoluble particle near a s/l interface. These predictions would then be used to define the minimum gravity level (g) required to investigate the fundamental physics of interaction between a particle and a s/I interface. To satisfy this objective, steady state calculations were performed for different gravity levels and orientations with the gravity vector. ne furnace configuration used in this analysis is the proposed International Space Station Furnace, Quench Module Insert (QMI) 1. Results from a thermal model of the furnace core were used as initial boundary conditions for solidification modeling. General model of binary alloy solidification was based on the finite element code FIDAP. It was found that for the worst case orientation of 90 degrees with the gravity vector and a g level of 10(exp -4)g(sub o) (g(sub o) = 9.8 m/s(exp 2)) the dominant forces acting on the particle would be the fundamental drag and interfacial forces.

Time-Resolved Records of Magnetic Activity on the Pallasite Parent Body and Psyche

NASA Astrophysics Data System (ADS)

Bryson, J. F. J.; Nichols, C. I. O.; Herrero-Albillos, J.; Kronast, F.; Kasama, T.; Alimadadi, H.; van der Laan, G.; Nimmo, F.; Harrison, R. J.

2014-12-01

Although many small bodies apparently generated dynamo fields in the early solar system, the nature and temporal evolution of these fields has remained enigmatic. Time-resolved records of the Earth's planetary field have been essential in understanding the dynamic history of our planet, and equivalent information from asteroids could provide a unique insight into the development of the solar system. Here we present time-resolved records of magnetic activity on the main-group pallasite parent body and (16) Psyche, obtained using newly-developed nanomagnetic imaging techniques. For the pallasite parent body, the inferred field direction remained relatively constant and the intensity was initially stable at ~100 μT before it decreased in two discrete steps down to 0 μT. We interpret this behaviour as due to vigorous dynamo activity driven by compositional convection in the core, ultimately transitioning from a dipolar to multipolar field as the inner core grew from the bottom-up. For Psyche (measured from IVA iron meteorites), the inferred field direction reversed, while the intensity remained stable at >50 μT. Psyche cooled rapidly as an unmantled core, although the resulting thermal convection alone cannot explain these observations. Instead, this behaviour required top-down core solidification, and is attributed either to compositional convection (if the core also solidified from the bottom-up) or convection generated directly by top-down solidification (e.g. Fe-snow). The mechanism governing convection in small body cores is an open question (due partly to uncertainties in the direction of core solidification), and these observations suggest that unconventional (i.e. not thermal) mechanisms acted in the early solar system. These mechanisms are very efficient at generating convection, implying a long-lasting and widespread epoch of dynamo activity among small bodies in the early solar system.

Atomistic to continuum modeling of solidification microstructures

DOE PAGES

Karma, Alain; Tourret, Damien

2015-09-26

We summarize recent advances in modeling of solidification microstructures using computational methods that bridge atomistic to continuum scales. We first discuss progress in atomistic modeling of equilibrium and non-equilibrium solid–liquid interface properties influencing microstructure formation, as well as interface coalescence phenomena influencing the late stages of solidification. The latter is relevant in the context of hot tearing reviewed in the article by M. Rappaz in this issue. We then discuss progress to model microstructures on a continuum scale using phase-field methods. We focus on selected examples in which modeling of 3D cellular and dendritic microstructures has been directly linked tomore » experimental observations. Finally, we discuss a recently introduced coarse-grained dendritic needle network approach to simulate the formation of well-developed dendritic microstructures. The approach reliably bridges the well-separated scales traditionally simulated by phase-field and grain structure models, hence opening new avenues for quantitative modeling of complex intra- and inter-grain dynamical interactions on a grain scale.« less

Crystal growth and furnace analysis

NASA Technical Reports Server (NTRS)

Dakhoul, Youssef M.

1986-01-01

A thermal analysis of Hg/Cd/Te solidification in a Bridgman cell is made using Continuum's VAST code. The energy equation is solved in an axisymmetric, quasi-steady domain for both the molten and solid alloy regions. Alloy composition is calculated by a simplified one-dimensional model to estimate its effect on melt thermal conductivity and, consequently, on the temperature field within the cell. Solidification is assumed to occur at a fixed temperature of 979 K. Simplified boundary conditions are included to model both the radiant and conductive heat exchange between the furnace walls and the alloy. Calculations are performed to show how the steady-state isotherms are affected by: the hot and cold furnace temperatures, boundary condition parameters, and the growth rate which affects the calculated alloy's composition. The Advanced Automatic Directional Solidification Furnace (AADSF), developed by NASA, is also thermally analyzed using the CINDA code. The objective is to determine the performance and the overall power requirements for different furnace designs.

Purification of silicon for photovoltaic applications

NASA Astrophysics Data System (ADS)

Delannoy, Yves

2012-12-01

Solar grade silicon, as a starting material for crystallization to produce solar cells, is discussed here in terms of impurities whose maximum content is estimated from recent literature and conferences. A review of the production routes for each category of solar-grade silicon (undoped, compensated or heavily compensated) is proposed with emphasis on the metallurgical route. Some recent results are proposed concerning segregation, showing that directional solidification systems can be used for solidification even at high solidification rate (15 cm/h). Results on inductive plasma purification, where boron is evacuated as HBO in a gas phase blown from an inductive plasma torch, are shown to apply as well to arc plasmas and purification by moist gas. Special attention is paid to the history of impurities in the purification processes, showing that impure auxiliary phases (silicon tetrachloride, slag, aluminum, etc.) often need their own purification process to enable their recycling, which has to be considered to evaluate the cost (financial, energetic and environmental) of the purification route.

Directional solidification of eutectic composites in space environment

NASA Technical Reports Server (NTRS)

Yue, A. S.

1972-01-01

The Ni-Ni3Ta eutectic and a nickel-base alloy containing 30 wt pct Ta were solidified unidirectionally in an electron beam floating zone melting apparatus. It was found that the volume fraction of the Ni3Ta phase in the Ni-Ni3Ta eutectic mixture was increased from 7.6 to 36 volume pct in agreement with the theory as predicted. Tensile properties of the randomly solidified and unidirectionally solidified Ni-Ni3Ta eutectic were determined as function of solidification rate and temperature. It was found that the ultimate tensile strength decreased as both the test temperature and solidification rate increased. An elongation of 40 pct was obtained for a nickelbase alloy containing 30 wt at room temperature. This unusually large elongation was attributed to the superplastic behavior of the alloy. The critical currents versus the external fields at 2.5, 3.0, 3.5 and 4.2 deg for the unidirectionally solidified Pb-Sn eutectic were measured. The values of critical fields at zero critical currents were obtained by extrapolation.

Solidification and crystal growth of solid solution semiconducting alloys

NASA Technical Reports Server (NTRS)

Lehoczky, S. L.; Szofran, F. R.

1984-01-01

Problems associated with the solidification and crytal growth of solid-solution semiconducting alloy crystals in a terrestrial environment are described. A detailed description is given of the results for the growth of mercury cadmium telluride (HgCdTe) alloy crystals by directional solidification, because of their considerable technological importance. A series of HgCdTe alloy crystals are grown from pseudobinary melts by a vertical Bridgman method using a wide range of growth rates and thermal conditions. Precision measurements are performed to establish compositional profiles for the crystals. The compositional variations are related to compositional variations in the melts that can result from two-dimensional diffusion or density gradient driven flow effects ahead of the growth interface. These effects are discussed in terms of the alloy phase equilibrium properties, the recent high temperature thermophysical data for the alloys and the highly unusual heat transfer characteristics of the alloy/ampule/furnace system that may readily lead to double diffusive convective flows in a gravitational environment.

Thermosolutal convection during dendritic solidification

NASA Technical Reports Server (NTRS)

Heinrich, J. C.; Nandapurkar, P.; Poirier, D. R.; Felicelli, S.

1989-01-01

This paper presents a mathematical model for directional solidification of a binary alloy including a dendritic region underlying an all-liquid region. It is assumed initially that there exists a nonconvecting state with planar isotherms and isoconcentrates solidifying at a constant velocity. The stability of this system has been analyzed and nonlinear calculations are performed that show the effect of convection in the solidification process when the system is unstable. Results of calculations for various cases defined by the initial temperature gradient at the dendrite tips and varying strength of the gravitational field are presented for systems involving lead-tin alloys. The results show that the systems are stable for a gravitational constant of 0.0001 g(0) and that convection can be suppressed by appropriate choice of the container's size for higher values of the gravitational constant. It is also concluded that for the lead-tin systems considered, convection in the mushy zone is not significant below the upper 20 percent of the dendritic zone, if al all.

Solidification of radioactive waste resins using cement mixed with organic material

DOE Office of Scientific and Technical Information (OSTI.GOV)

Laili, Zalina, E-mail: liena@nm.gov.my; Waste and Environmental Technology Division, Malaysian Nuclear Agency; Yasir, Muhamad Samudi

2015-04-29

Solidification of radioactive waste resins using cement mixed with organic material i.e. biochar is described in this paper. Different percentage of biochar (0%, 5%, 8%, 11%, 14% and 18%) was investigated in this study. The characteristics such as compressive strength and leaching behavior were examined in order to evaluate the performance of solidified radioactive waste resins. The results showed that the amount of biochar affect the compressive strength of the solidified resins. Based on the data obtained for the leaching experiments performed, only one formulation showed the leached of Cs-134 from the solidified radioactive waste resins.

An advanced material science payload for GAS

NASA Technical Reports Server (NTRS)

Joensson, R.; Wallin, S.; Loeth, K.

1986-01-01

The aim of the experiment is to study solidification of different compositions of lead-tin. The weight of the material is quite high: 8 kilograms. Nearly 10% of the payload is sample weight. The dendritic growth and the effect of the absence of natural convection are of particular interest. The results from the flight processed samples will be compared with results from Earth processed samples in order to investigate the influence of the natural convection on the solidification process. The power systems, heat storage and rejection, and mechanical support are discussed in relationship to the scientific requirements.

Low-gravity homogenization and solidification of aluminum antimonide. [Apollo-Soyuz test project

NASA Technical Reports Server (NTRS)

Ang, C.-Y.; Lacy, L. L.

1976-01-01

The III-V semiconducting compound AlSb shows promise as a highly efficient solar cell material, but it has not been commercially exploited because of difficulties in compound synthesis. Liquid state homogenization and solidification of AlSb were carried out in the Apollo-Soyuz Test Project Experiment MA-044 in the hope that compositional homogeneity would be improved by negating the large density difference between the two constituents. Post-flight analysis and comparative characterization of the space-processed and ground-processed samples indicate that there are major homogeneity improvements in the low-gravity solidified material.

Modeling of microstructure evolution in direct metal laser sintering: A phase field approach

NASA Astrophysics Data System (ADS)

Nandy, Jyotirmoy; Sarangi, Hrushikesh; Sahoo, Seshadev

2017-02-01

Direct Metal Laser Sintering (DMLS) is a new technology in the field of additive manufacturing, which builds metal parts in a layer by layer fashion directly from the powder bed. The process occurs within a very short time period with rapid solidification rate. Slight variations in the process parameters may cause enormous change in the final build parts. The physical and mechanical properties of the final build parts are dependent on the solidification rate which directly affects the microstructure of the material. Thus, the evolving of microstructure plays a vital role in the process parameters optimization. Nowadays, the increase in computational power allows for direct simulations of microstructures during materials processing for specific manufacturing conditions. In this study, modeling of microstructure evolution of Al-Si-10Mg powder in DMLS process was carried out by using a phase field approach. A MATLAB code was developed to solve the set of phase field equations, where simulation parameters include temperature gradient, laser scan speed and laser power. The effects of temperature gradient on microstructure evolution were studied and found that with increase in temperature gradient, the dendritic tip grows at a faster rate.

Development of a direct patterning method for functional oxide thin films using ultraviolet irradiation and hybrid-cluster gels and its application to thin-film transistor fabrication

NASA Astrophysics Data System (ADS)

Yoshimoto, Yuuki; Li, Jinwang; Shimoda, Tatsuya

2018-04-01

A gel state exists in the solution-solid conversion process. We found that solidification can be promoted by irradiating the gel with ultraviolet (UV) light. In this study, a patterning method without using a vacuum system or employing photoresist materials has been proposed wherein solidification was applied to a gel by UV irradiation. Indium oxide gel, indium gallium oxide gel, lanthanum zirconium oxide gel, and lanthanum ruthenium oxide gels were successfully patterned by using our technique. Moreover, an oxide thin-film transistor was fabricated by our novel patterning method and was successfully operated.

Heat of mixing and morphological stability

NASA Technical Reports Server (NTRS)

Nandapurkar, P.; Poirier, D. R.

1988-01-01

A mathematical model, which incorporates heat of mixing in the energy balance, has been developed to analyze the morphological stability of a planar solid-liquid interface during the directional solidification of a binary alloy. It is observed that the stability behavior is almost that predicted by the analysis of Mullins and Sekerka (1963) at low growth velocities, while deviations in the critical concentration of about 20-25 percent are observed under rapid solidification conditions for certain systems. The calculations indicate that a positive heat of mixing makes the planar interface more unstable, whereas a negative heat of mixing makes it more stable, in terms of the critical concentration.

Fluid Dynamics and Solidification of Molten Solder Droplets Impacting on a Substrate in Microgravity

NASA Technical Reports Server (NTRS)

Megardis, C. M.; Poulikakos, D.; Diversiev, G.; Boomsma, K.; Xiong, B.; Nayagam, V.

1999-01-01

This program investigates the fluid dynamics and simultaneous solidification of molten solder droplets impacting on a flat smooth substrate. The problem of interest is directly relevant to the printing of microscopic solder droplets in surface mounting of microelectronic devices. The study consists of a theoretical and an experimental component. The theoretical work uses axisymmetric Navier-Stokes models based on finite element techniques. The experimental work will be ultimately performed in microgravity in order to allow for the use of larger solder droplets which make feasible the performance of accurate measurements, while maintaining similitude of the relevant fluid dynamics groups (Re, We).

Fluid Dynamics and Solidification of Molten Solder Droplets Impacting on a Substrate in Microgravity

NASA Technical Reports Server (NTRS)

Poulikakos, Dimos; Megaridis, Constantine M.; Vedha-Nayagam, M.

1996-01-01

This program investigates the fluid dynamics and simultaneous solidification of molten solder droplets impacting on a flat substrate. The problem of interest is directly relevant to the printing of microscopic solder droplets in surface mounting of microelectronic devices. The study consists of a theoretical and an experimental component. The theoretical work uses axisymmetric Navier-Stokes models based on finite element techniques. The experimental work is performed in microgravity to allow for the use of larger solder droplets that make feasible the performance of accurate measurements while maintaining similitude of the relevant fluid dynamics groups (Re, We) and keeping the effect of gravity negligible.

Dynamics of spacing adjustment and recovery mechanisms of ABAC-type growth pattern in ternary eutectic systems

NASA Astrophysics Data System (ADS)

Mohagheghi, Samira; Şerefoğlu, Melis

2017-07-01

In directionally solidified 2D samples at ternary eutectic compositions, the stable three-phase pattern is established to be lamellar structure with ABAC stacking, where A, B, and C are crystalline phases. Beyond the stability limits of the ABAC pattern, the system uses various spacing adjustment mechanisms to revert to the stable regime. In this study, the dynamics of spacing adjustment and recovery mechanisms of isotropic ABAC patterns were investigated using three-phase In-Bi-Sn alloy. Unidirectional solidification experiments were performed on 23.0 and 62.7 μm-thick samples, where solidification front was monitored in real-time from both sides of the sample using a particular microscopy system. At these thicknesses, the pattern was found to be 2D during steady-state growth, i.e. both top and bottom microstructures were the same. However, during spacing adjustment and recovery mechanisms, 3D features were observed. Dynamics of two major instabilities, lamellae branching and elimination, were quantified. After these instabilities, two key ABAC pattern recovery mechanisms, namely, phase invasion and phase exchange processes, were identified and analyzed. After elimination, ABAC pattern is recovered by either continuous eliminations of all phases or by phase exchange. After branching, the recovery mechanisms are established to be phase invasion and phase exchange.

Three-Dimensional Stereoscopic Tracking Velocimetry and Experimental/Numerical Comparison of Directional Solidification

NASA Technical Reports Server (NTRS)

Lee, David; Ge, Yi; Cha, Soyoung Stephen; Ramachandran, Narayanan; Rose, M. Franklin (Technical Monitor)

2001-01-01

Measurement of three-dimensional (3-D) three-component velocity fields is of great importance in both ground and space experiments for understanding materials processing and fluid physics. The experiments in these fields most likely inhibit the application of conventional planar probes for observing 3-D phenomena. Here, we present the investigation results of stereoscopic tracking velocimetry (STV) for measuring 3-D velocity fields, which include diagnostic technology development, experimental velocity measurement, and comparison with analytical and numerical computation. STV is advantageous in system simplicity for building compact hardware and in software efficiency for continual near-real-time monitoring. It has great freedom in illuminating and observing volumetric fields from arbitrary directions. STV is based on stereoscopic observation of particles-Seeded in a flow by CCD sensors. In the approach, part of the individual particle images that provide data points is likely to be lost or cause errors when their images overlap and crisscross each other especially under a high particle density. In order to maximize the valid recovery of data points, neural networks are implemented for these two important processes. For the step of particle overlap decomposition, the back propagation neural network is utilized because of its ability in pattern recognition with pertinent particle image feature parameters. For the step of particle tracking, the Hopfield neural network is employed to find appropriate particle tracks based on global optimization. Our investigation indicates that the neural networks are very efficient and useful for stereoscopically tracking particles. As an initial assessment of the diagnostic technology performance, laminar water jets with and without pulsation are measured. The jet tip velocity profiles are in good agreement with analytical predictions. Finally, for testing in material processing applications, a simple directional solidification apparatus is built for experimenting with a metal analog of succinonitrile. Its 3-D velocity field at the liquid phase is then measured to be compared with those from numerical computation. Our theoretical, numerical, and experimental investigations have proven STV to be a viable candidate for reliably measuring 3-D flow velocities. With current activities are focused on further improving the processing efficiency, overall accuracy, and automation, the eventual efforts of broad experimental applications and concurrent numerical modeling validation will be vital to many areas in fluid flow and materials processing.

Fabrication, properties, and applications of porous metals with directional pores

PubMed Central

NAKAJIMA, Hideo

2010-01-01

Lotus-type porous metals with aligned long cylindrical pores are fabricated by unidirectional solidification from the melt with a dissolved gas such as hydrogen, nitrogen, or oxygen. The gas atoms can be dissolved into the melt via a pressurized gas atmosphere or thermal decomposition of gaseous compounds. Three types of solidification techniques have been developed: mold casting, continuous zone melting, and continuous casting techniques. The last method is superior from the viewpoint of mass production of lotus metals. The observed anisotropic behaviors of the mechanical properties, sound absorption, and thermal conductivity are inherent to the anisotropic porous structure. In particular, the remarkable anisotropy in the mechanical strength is attributed to the stress concentration around the pores aligned perpendicular to the loading direction. Heat sinks are a promising application of lotus metals due to the high cooling performance with a large heat transfer. PMID:21084772

Transparent metal model study of the use of a cellular growth front to form aligned monotectic composite materials

NASA Technical Reports Server (NTRS)

Kaukler, William F.

1988-01-01

The purpose of this work was to resolve a scientific controversy in the understanding of how second phase particles become aligned during unidirectional growth of a monotectic alloy. A second aspect was to make the first systematic observations of the solidification behavior of a monotectic alloy during cellular growth in-situ. This research provides the first systematic transparent model study of cellular solidification. An interface stability diagram was developed for the planar to cellular transition of the succinonitrile glycerol (SNG) system. A method was developed utilizing Fourier Transform Infrared Spectroscopy which allows quantitative compositional analysis of directionally solidified SNG along the growth axis. To determine the influence of cellular growth front on alignment for directionally solidified monotectic alloys, the planar and cellular growth morphology was observed in-situ for SNG between 8 and 17 percent glycerol and for a range of over two orders of magnitude G/R.

Investigation of temperature and concentration oscillations in the directional solidification of Pb-Sn-Te

NASA Technical Reports Server (NTRS)

Anderson, T. J.; Narayanan, R.

1987-01-01

Directional solidification of the pseudobinary compound semiconductor material Pb sub 1-x Sn sub x Te by the Bridgman crystal growth process will be studied. Natural convection in the molten sample will be visualized with a novel electrochemical cell technique that employs the solid electrolyte material yttria-stabilized zirconia. Mass transfer by both diffusion and convection will be measured by detecting the motion of oxygen tracer in the liquid. Additional applications for electrochemical cells in semiconductor crystal growth are suggested. Unsteady convection in the melt will also be detected by the appearance of temperature oscillations. The purpose of this study is to experimentally characterize the overstable conditions for a Pb sub 1-x Sn sub x Te melt in the vertical Bridgman crystal growth technique and use a linear analysis to predict the onset of convection for this system.

Fabrication, properties, and applications of porous metals with directional pores.

PubMed

Nakajima, Hideo

2010-01-01

Lotus-type porous metals with aligned long cylindrical pores are fabricated by unidirectional solidification from the melt with a dissolved gas such as hydrogen, nitrogen, or oxygen. The gas atoms can be dissolved into the melt via a pressurized gas atmosphere or thermal decomposition of gaseous compounds. Three types of solidification techniques have been developed: mold casting, continuous zone melting, and continuous casting techniques. The last method is superior from the viewpoint of mass production of lotus metals. The observed anisotropic behaviors of the mechanical properties, sound absorption, and thermal conductivity are inherent to the anisotropic porous structure. In particular, the remarkable anisotropy in the mechanical strength is attributed to the stress concentration around the pores aligned perpendicular to the loading direction. Heat sinks are a promising application of lotus metals due to the high cooling performance with a large heat transfer.

Predicting Microstructure and Microsegregation in Multicomponent Aluminum Alloys

NASA Astrophysics Data System (ADS)

Yan, Xinyan; Ding, Ling; Chen, ShuangLin; Xie, Fanyou; Chu, M.; Chang, Y. Austin

Accurate predictions of microstructure and microsegregation in metallic alloys are highly important for applications such as alloy design and process optimization. Restricted assumptions concerning the phase diagram could easily lead to erroneous predictions. The best approach is to couple microsegregation modeling with phase diagram computations. A newly developed numerical model for the prediction of microstructure and microsegregation in multicomponent alloys during dendritic solidification was introduced. The micromodel is directly coupled with phase diagram calculations using a user-friendly and robust phase diagram calculation engine-PANDAT. Solid state back diffusion, undercooling and coarsening effects are included in this model, and the experimentally measured cooling curves are used as the inputs to carry out the calculations. This model has been used to predict the microstructure and microsegregation in two multicomponent aluminum alloys, 2219 and 7050. The calculated values were confirmed using results obtained from directional solidification.

Towards graphite-free hot zone for directional solidification of silicon

NASA Astrophysics Data System (ADS)

Dropka, Natasha; Buchovska, Iryna; Herrmann-Geppert, Iris; Klimm, Detlef; Kiessling, Frank M.; Degenhardt, Ulrich

2018-06-01

The reduction of SiC, Si3N4 and transition metals impurities in directionally solidified Si ingots poses one of the crucial challenges in the solar cells production. Particularly strong contamination comes from the graphite parts in the hot zone. Therefore, we selected three massive ceramic materials to replace graphite, developed the novel design of the crucible support and cover and compared the crystals grown in them with ingots from the standard graphite design. The experiments were performed for phosphorus n-doped silicon of G0 size. The ingots were compared with respect to O- and C-content, metal impurities, resistivity and lifetime. The superior performance of TiC relative to other ceramics was observed, particularly due to the lower concentration of substitutional carbon in Si ingot (up to 2.6 times) and the higher minority carrier lifetime of (up to 4.4 times) with narrow red zones.

Three-Dimensional Dendrite Growth Within the Shrouds of Single Crystal Blades of a Nickel-Based Superalloy

NASA Astrophysics Data System (ADS)

Wang, Fu; Wu, Zining; Huang, Can; Ma, Dexin; Jakumeit, Jürgen; Bührig-Polaczek, Andreas

2017-12-01

The effect of withdrawal rates on the three-dimensional dendrite growth within the shrouds of single crystal blades during directional solidification was studied by both experiments and numerical simulations. The results showed that at given withdrawal rates, the dendrite pattern within the shrouds comprised three zones: primary dendrite zone, secondary dendrite spread zone, and a higher-order dendrite branched zone. With increasing withdrawal rate, the average primary dendrite arm spacing in the primary dendrite zone and the average secondary dendrite arm spacings in both the secondary dendrite spread zone and the higher-order dendrite branched zone were reduced. Independent of the variation in withdrawal rate, two analogous dendrite growth routes were observed within the shrouds of the employed blade geometry. These routes originated from the primary dendrites in the primary dendrite zone and filled in the shrouds by directly spreading secondary or successively branching higher-order dendrites. Except for a withdrawal rate of 6 mm min-1, these dendrites impinged at the shroud's highest extremity and could be explained by the simulated moving isotherms. As the withdrawal rate was increased to 2.5 mm min-1, undercooling and contraction stress-related equiaxed grains were observed in the interdendritic region at the lowest shroud extremity. With increasing withdrawal rate, the amount of the defects was increased. Since the defects destroy the integrity of single crystal blades, the solidification condition within the shroud should be controlled to avoid their occurrence. Along the dendrite growth route, an accumulated misorientation of the dendrites was observed. At the same positions, this accumulation increased with increasing withdrawal rate.

Application of Solidification Theory to Rapid Solidification Processing

DTIC Science & Technology

1984-07-01

solubility; _NiAl -Cr quasibinary alloys ; Rapid solidification ; Solidification theory I’.ASRACT ICfene an roerso aid it 000e..yV SON identify0 by Week...110100a) ~j ~apid solidification allows the production of alloys with new compositions and * uphases and also allows production of improved alloys by...control of microstructure;L and homogeneity. The effect of rapid solidification velocity on the micro- structure of Ag-Cu alloys is comprehensively

Simulation of the as-cast structure of Al-4.0wt.%Cu ingots with a 5-phase mixed columnar-equiaxed solidification model

NASA Astrophysics Data System (ADS)

Wu, M.; Ahmadein, M.; Kharicha, A.; Ludwig, A.; Li, J. H.; Schumacher, P.

2012-07-01

Empirical knowledge about the formation of the as-cast structure, mostly obtained before 1980s, has revealed two critical issues: one is the origin of the equiaxed crystals; one is the competing growth of the columnar and equiaxed structures, and the columnar-to-equiaxed transition (CET). Unfortunately, the application of empirical knowledge to predict and control the as-cast structure was very limited, as the flow and crystal transport were not considered. Therefore, a 5-phase mixed columnar-equiaxed solidification model was recently proposed by the current authors based on modeling the multiphase transport phenomena. The motivation of the recent work is to determine and evaluate the necessary modeling parameters, and to validate the mixed columnar-equiaxed solidification model by comparison with laboratory castings. In this regard an experimental method was recommended for in-situ determination of the nucleation parameters. Additionally, some classical experiments of the Al-Cu ingots were conducted and the as-cast structural information including distinct columnar and equiaxed zones, macrosegregation, and grain size distribution were analysed. The final simulation results exhibited good agreement with experiments in the case of high pouring temperature, whereas disagreement in the case of low pouring temperature. The reasons for the disagreement are discussed.

Undercooling-Induced macrosegregation in directional solidification

NASA Astrophysics Data System (ADS)

de Groh, Henry C.

1994-11-01

The accepted primary mechanism for causing macrosegregation in directional solidification (DS) is thermal and solutal convection in the liquid. This article demonstrates the effects of under-cooling and nucleation on macrosegregation and shows that undercooling, in some cases, can be the cause of end-to-end macrosegregation. Alloy ingots of Pb-Sn were directionally solidified upward and downward, with and without undercooling. A thermal gradient of about 5.1 K/cm and a cooling rate of 7.7 K/h were used. Crucibles of borosilicate glass, stainless steel with Cu bottoms, and fused silica were used. High undercoolings were achieved in the glass crucibles, and very low undercoolings were achieved in the steel/Cu crucible. During under-cooling, large, coarse Pb dendrites were found to be present. Large amounts of macrosegregation developed in the undercooled eutectic and hypoeutectic alloys. This segre-gation was found to be due to the nucleation and growth of primary Pb-rich dendrites, continued coarsening of Pb dendrites during undercooling of the interdendritic liquid, Sn enrichment of the liquid, and dendritic fragmentation and settling during and after recalescence. Eutectic ingots that solidified with no undercooling had no macrosegregation, because both Pb and Sn phases were effectively nucleated at the start of solidification, thus initiating the growth of solid of eutectic composition. It is thus shown that undercooling and single-phase nucleation can cause significant macrosegregation by increasing the amount of solute rejected into the liquid and by the movement of unattached dendrites and dendrite fragments, and that macrosegregation in excess of what would be expected due to diffusion transport is not necessarily caused by convection in the liquid.

Experimental Studies of Heat-Transfer Behavior at a Casting/Water-Cooled-Mold Interface and Solution of the Heat-Transfer Coefficient

NASA Astrophysics Data System (ADS)

Zeng, Y. D.; Wang, F.

2018-02-01

In this paper, we propose an experimental model for forming an air gap at the casting/mold interface during the solidification process of the casting, with the size and formation time of the air gap able to be precisely and manually controlled. Based on this model, experiments of gravity casting were performed, and on the basis of the measured temperatures at different locations inside the casting and the mold, the inverse analysis method of heat transfer was applied to solve for the heat-transfer coefficient at the casting/mold interface during the solidification process. Furthermore, the impacts of the width and formation time of the air gap on the interface heat-transfer coefficient (IHTC) were analyzed. The results indicate that the experimental model succeeds in forming an air gap having a certain width at any moment during solidification of the casting, thus allowing us to conveniently and accurately study the impact of the air gap on IHTC using the model. In addition, the casting/mold IHTC is found to first rapidly decrease as the air gap forms and then slowly decrease as the solidification process continues. Moreover, as the width of the air gap and the formation time of the air gap increase, the IHTC decreases.

Microstructure formation in partially melted zone during gas tungsten arc welding of AZ91 Mg cast alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhu Tianping; Chen, Zhan W.; Gao Wei

2008-11-15

During gas tungsten arc (GTA) welding of AZ91 Mg cast alloy, constitutional liquid forms locally in the original interdendritic regions in the partially melted zone (PMZ). The PMZ re-solidification behaviour has not been well understood. In this study, the gradual change of the re-solidification microstructure within PMZ from base metal side to weld metal side was characterised. High cooling rate experiments using Gleeble thermal simulator were also conducted to understand the morphological change of the {alpha}-Mg/{beta}-Mg{sub 17}Al{sub 12} phase interface formed during re-solidification after partial melting. It was found that the original partially divorced eutectic structure has become a moremore » regular eutectic phase in most of the PMZ, although close to the fusion boundary the re-solidified eutectic is again a divorced one. Proceeding the eutectic re-solidification, if the degree of partial melting is sufficiently high, {alpha}-Mg re-solidified with a cellular growth, resulting in a serrated interface between {alpha}-Mg and {alpha}-Mg/{beta}-Mg{sub 17}Al{sub 12} in the weld sample and between {alpha}-Mg and {beta}-Mg{sub 17}Al{sub 12} (fully divorced eutectic) in Gleeble samples. The morphological changes affected by the peak temperature and cooling rate are also explained.« less

Solidification of Undercooled Melts of Al-Based Alloys on Earth and in Space

NASA Astrophysics Data System (ADS)

Herlach, Dieter M.; Burggraf, Stefan; Galenko, Peter; Gandin, Charles-André; Garcia-Escorial, Asuncion; Henein, Hani; Karrasch, Christian; Mullis, Andrew; Rettenmayr, Markus; Valloton, Jonas

2017-08-01

Containerless processing of droplets and drops by atomization and electromagnetic levitation are applied to undercool metallic melts and alloys prior to solidification. Heterogeneous nucleation on crucible walls is completely avoided giving access to large undercoolings. Experiments are performed both under terrestrial (1 g) conditions and in reduced gravity ( µg) as well. Microgravity conditions are realized by the free fall of small droplets during atomization of a spray of droplets, individual drops in a drop tube and by electromagnetic levitation of drops during parabolic flights, sounding rocket missions, and using the electro-magnetic levitator multi-user facility on board the International Space Station. The comparison of both sets of experiments in 1 g and µg leads to an estimation of the influence of forced convection on dendrite growth kinetics and microstructure evolution.

Heat flow control and segregation in directional solidification: Development of an experimental and theoretical basis for Bridgman-type growth experiments in a microgravity environment

NASA Technical Reports Server (NTRS)

Witt, A. F.

1986-01-01

Within the framework of the proposed research, emphasis was placed on application of magnetic fields to semiconductor growth systems. It was found that magnetic fields up to 3 kGauss do not affect the growth behavior nor the macro-segregation behavior in the system Ge(Ga). Applied fields are found to significantlty alter the radial dopant distribution, which is attributed to alterations in the spatial orientation of convective cells. Increasing the magnetic field to 30 kGauss is found to have a fundamental effect on dopant segregation. Emphasis is also placed on the potential of KC-135 flights for preliminary studies on the effects of reduced gravity environments on the wetting behavior of semiconductor systems in growth configuration. The limited number of experiments conducted does not allow any conclusions on the merits of KC-135 flights for semiconductor processing research.

Determination of crystal growth rates during rapid solidification of polycrystalline aluminum by nano-scale spatio-temporal resolution in situ transmission electron microscopy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zweiacker, K.; McKeown, J. T.; Liu, C.

In situ investigations of rapid solidification in polycrystalline Al thin films were conducted using nano-scale spatio-temporal resolution dynamic transmission electron microscopy. Differences in crystal growth rates and asymmetries in melt pool development were observed as the heat extraction geometry was varied by controlling the proximity of the laser-pulse irradiation and the associated induced melt pools to the edge of the transmission electron microscopy support grid, which acts as a large heat sink. Experimental parameters have been established to maximize the reproducibility of the material response to the laser-pulse-related heating and to ensure that observations of the dynamical behavior of themore » metal are free from artifacts, leading to accurate interpretations and quantifiable measurements with improved precision. Interface migration rate measurements revealed solidification velocities that increased consistently from ~1.3 m s –1 to ~2.5 m s –1 during the rapid solidification process of the Al thin films. Under the influence of an additional large heat sink, increased crystal growth rates as high as 3.3 m s –1 have been measured. The in situ experiments also provided evidence for development of a partially melted, two-phase region prior to the onset of rapid solidification facilitated crystal growth. As a result, using the experimental observations and associated measurements as benchmarks, finite-element modeling based calculations of the melt pool evolution after pulsed laser irradiation have been performed to obtain estimates of the temperature evolution in the thin films.« less

Determination of crystal growth rates during rapid solidification of polycrystalline aluminum by nano-scale spatio-temporal resolution in situ transmission electron microscopy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zweiacker, K., E-mail: Kai@zweiacker.org; Liu, C.; Wiezorek, J. M. K.

In situ investigations of rapid solidification in polycrystalline Al thin films were conducted using nano-scale spatio-temporal resolution dynamic transmission electron microscopy. Differences in crystal growth rates and asymmetries in melt pool development were observed as the heat extraction geometry was varied by controlling the proximity of the laser-pulse irradiation and the associated induced melt pools to the edge of the transmission electron microscopy support grid, which acts as a large heat sink. Experimental parameters have been established to maximize the reproducibility of the material response to the laser-pulse-related heating and to ensure that observations of the dynamical behavior of themore » metal are free from artifacts, leading to accurate interpretations and quantifiable measurements with improved precision. Interface migration rate measurements revealed solidification velocities that increased consistently from ∼1.3 m s{sup −1} to ∼2.5 m s{sup −1} during the rapid solidification process of the Al thin films. Under the influence of an additional large heat sink, increased crystal growth rates as high as 3.3 m s{sup −1} have been measured. The in situ experiments also provided evidence for development of a partially melted, two-phase region prior to the onset of rapid solidification facilitated crystal growth. Using the experimental observations and associated measurements as benchmarks, finite-element modeling based calculations of the melt pool evolution after pulsed laser irradiation have been performed to obtain estimates of the temperature evolution in the thin films.« less

Determination of crystal growth rates during rapid solidification of polycrystalline aluminum by nano-scale spatio-temporal resolution in situ transmission electron microscopy

DOE PAGES

Zweiacker, K.; McKeown, J. T.; Liu, C.; ...

2016-08-04

In situ investigations of rapid solidification in polycrystalline Al thin films were conducted using nano-scale spatio-temporal resolution dynamic transmission electron microscopy. Differences in crystal growth rates and asymmetries in melt pool development were observed as the heat extraction geometry was varied by controlling the proximity of the laser-pulse irradiation and the associated induced melt pools to the edge of the transmission electron microscopy support grid, which acts as a large heat sink. Experimental parameters have been established to maximize the reproducibility of the material response to the laser-pulse-related heating and to ensure that observations of the dynamical behavior of themore » metal are free from artifacts, leading to accurate interpretations and quantifiable measurements with improved precision. Interface migration rate measurements revealed solidification velocities that increased consistently from ~1.3 m s –1 to ~2.5 m s –1 during the rapid solidification process of the Al thin films. Under the influence of an additional large heat sink, increased crystal growth rates as high as 3.3 m s –1 have been measured. The in situ experiments also provided evidence for development of a partially melted, two-phase region prior to the onset of rapid solidification facilitated crystal growth. As a result, using the experimental observations and associated measurements as benchmarks, finite-element modeling based calculations of the melt pool evolution after pulsed laser irradiation have been performed to obtain estimates of the temperature evolution in the thin films.« less

Laser weldability of 21Cr-6Ni-9Mn stainless steel: Part I - Impurity effects and solidifcation mode

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tate, Stephen B.; Javernick, Daniel Anthony; Lienert, Thomas J.

For laser welded type 21Cr-6Ni-9Mn (21-6-9) stainless steels, the relationship between solidification cracking susceptibility and chemical composition was examined, and primary solidification mode (PSM) diagrams were developed to predict solidification mode. Sigmajig testing was used with experimental heats of type 21-6-9 to determine the effect of P and S on solidification cracking w hen primary austenite solidification occurred. Phosphorus showed a larger influence on solidification cracking relative to S, and a relationship of (P+0.2S ) was found for total impurity content. PSM diagrams to predict solidification mode were developed by analyzing welds made at three travel speeds for a widemore » range of 21-6-9 alloys and some other similar alloys. The minimum Cr eq/Ni eq required for primary ferrite solidification increased as travel speed increased, with more alloys showing primary austenite solidification at higher travel rates. Furthermore, as travel speed increased from 21 to 85 mm/s, the average solidification rate increased from 6 to 25 mm/s.« less

Laser weldability of 21Cr-6Ni-9Mn stainless steel: Part I - Impurity effects and solidifcation mode

DOE PAGES

Tate, Stephen B.; Javernick, Daniel Anthony; Lienert, Thomas J.; ...

2016-11-02

For laser welded type 21Cr-6Ni-9Mn (21-6-9) stainless steels, the relationship between solidification cracking susceptibility and chemical composition was examined, and primary solidification mode (PSM) diagrams were developed to predict solidification mode. Sigmajig testing was used with experimental heats of type 21-6-9 to determine the effect of P and S on solidification cracking w hen primary austenite solidification occurred. Phosphorus showed a larger influence on solidification cracking relative to S, and a relationship of (P+0.2S ) was found for total impurity content. PSM diagrams to predict solidification mode were developed by analyzing welds made at three travel speeds for a widemore » range of 21-6-9 alloys and some other similar alloys. The minimum Cr eq/Ni eq required for primary ferrite solidification increased as travel speed increased, with more alloys showing primary austenite solidification at higher travel rates. Furthermore, as travel speed increased from 21 to 85 mm/s, the average solidification rate increased from 6 to 25 mm/s.« less

Experiments Conducted Aboard the International Space Station: The Pore Formation and Mobility Investigation (PFMI) and the In-Space Soldering Investigation (ISSI): A Current Study of Results

NASA Technical Reports Server (NTRS)

Grugel, R. N.; Luz, P.; Smith, G. A.; Spivey, R.; Jeter, L.; Gillies, D. C> ; Hua, F.; Anilkumar, A. V.

2006-01-01

Experiments in support of the Pore Formation and Mobility Investigation (PFMI) and the In-Space Soldering Investigation (ISSI) were conducted aboard the International Space Station (ISS) with the goal of promoting our fundamental understanding of melting dynamics , solidification phenomena, and defect generation during materials processing in a microgravity environment. Through the course of many experiments a number of observations, expected and unexpected, have been directly made. These include gradient-driven bubble migration, thermocapillary flow, and novel microstructural development. The experimental results are presented and found to be in good agreement with models pertinent to a microgravity environment. Based on the space station results, and noting the futility of duplicating them in Earth s unit-gravity environment, attention is drawn to the role ISS experimentslhardware can play to provide insight to potential materials processing techniques and/or repair scenarios that might arise during long duration space transport and/or on the lunar/Mars surface.

Heat transfer enhancement for spent nuclear fuel assembly disposal packages using metallic void fillers: A prevention technique for solidification shrinkage-induced interfacial gaps

NASA Astrophysics Data System (ADS)

Park, Yongsoo; McKrell, Thomas J.; Driscoll, Michael J.

2017-06-01

This study considers replacing the externally accessible void spaces inside a disposal package containing a spent nuclear fuel assembly (SNFA) with high heat conducting metal to increase the effective thermal conductivity of the package and simplify the heat transfer mechanism inside the package by reducing it to a conduction dominant problem. The focus of the study is on preventing the gaps adjacent to the walls of the package components, produced by solidification shrinkage of poured liquid metal. We approached the problem by providing a temporary coating layer on the components to avoid direct build-up of thick metal oxides on their surface to promote metallic bonding at the interfaces under a non-inert environment. Laboratory scale experiments without SNFA were performed with Zn coated low carbon steel canisters and Zamak-3 void filler under two different filling temperature conditions - below and above the melting point of Zn (designated BMP and AMP respectively). Gap formation was successfully prevented in both cases while we confirmed an open gap in a control experiment, which used an uncoated canister. Minor growth of Al-Fe intermetallic phases was observed at the canister/filler interface of the sample produced under the BMP condition while their growth was significant and showed irregularly distributed morphology in the sample produced under the AMP condition, which has a potential to mitigate excessive residual stresses caused by shrinkage prevention. A procedure for the full-scale application was specified based on the results.

Dewetting and Segregation of Zn-Doped InSb in Microgravity Experiments

NASA Technical Reports Server (NTRS)

Ostrogorsky, A. G.; Marin, C.; Duffar, T.; Volz, M.

2009-01-01

In directional solidification, dewetting is characterized by the lack of contact between the crystal and the crucible walls, due to the existence of a liquid meniscus at the level of the solid-liquid interface. This creates a gap of a few tens of micrometers between the crystal and the crucible. One of the immediate consequences of this phenomenon is the dramatic improvement of the quality of the crystal. This improvement is partly due to the modification of the solid-liquid interface curvature and partly to the absence of sticking and spurious nucleation at the crystal-crucible interface. Dewetting has been, commonly observed during the growth of semiconductors in crucibles under microgravity conditions where it appears to be very stable: the gap between the crystal and the crucible remains constant along several centimetres of growth. The physical models of the phenomenon are well established and they predict that dewetting should not occur in microgravity, if sufficient static pressure is imposed on the melt, pushing it towards the crucible. We present the results of InSb(Zn) solidification experiments conducted at the International Space Station (ISS) where, in spite of a spring exerting a pressure on the liquid, partial dewetting did occur. This surprising result is discussed in terms of force exerted .by the spring on the liquid and of possibility that the spring did not work properly. Furthermore, it appears that the segregation of the Zn was not affected by the occurrence of the dewetting. The data suggest that there was no significant interference of convection with segregation of Zn in InSb.

Grain Refinement and Improvement of Solidification Defects in Direct-Chill Cast Billets of A4032 Alloy by Melt Conditioning

NASA Astrophysics Data System (ADS)

Li, Hu-Tian; Zhao, Pizhi; Yang, Rongdong; Patel, Jayesh B.; Chen, Xiangfu; Fan, Zhongyun

2017-10-01

Melt-conditioned, direct-chill (MC-DC) casting is an emerging technology to manipulate the solidification process by melt conditioning via intensive shearing in the sump during DC casting to tailor the solidification microstructure and defect formation. When using MC-DC casting technology in an industrial scale DC cast billet of an A4032 aluminum alloy, significant grain refinement and uniform microstructure can be achieved in the primary α-Al phase with fine secondary dendritic arm spacing (SDAS). Improved macrosegregation is quantitatively characterized and correlated with the suppression of channel segregation. The mechanisms for the prevention of channel segregation are attributed to the increased local cooling rate in the liquid-solid phase region in the sump and the formation of fine equiaxed dendritic grains under intensive melt shearing during MC-DC casting. A critical cooling rate has been identified to be around 0.5 to 1 K/s (°C/s) for the channel segregation to happen in the investigated alloy based on quantitative metallographic results of SDAS. Reduction and refinement of microporosity is attributed to the improved permeability in the liquid-solid phase region estimated by the Kozeny-Carman relationship. The potential improvement in the mechanical properties achievable in MC-DC cast billets is indicated by the finer and more uniform forging streamline in the forgings of MC-DC cast billet.

Towards wall functions for the prediction of solute segregation in plane front directional solidification

NASA Astrophysics Data System (ADS)

Chatelain, M.; Rhouzlane, S.; Botton, V.; Albaric, M.; Henry, D.; Millet, S.; Pelletier, D.; Garandet, J. P.

2017-10-01

The present paper focuses on solute segregation occurring in directional solidification processes with sharp solid/liquid interface, like silicon crystal growth. A major difficulty for the simulation of such processes is their inherently multi-scale nature: the impurity segregation problem is controlled at the solute boundary layer scale (micrometers) while the thermal problem is ruled at the crucible scale (meters). The thickness of the solute boundary layer is controlled by the convection regime and requires a specific refinement of the mesh of numerical models. In order to improve numerical simulations, wall functions describing solute boundary layers for convecto-diffusive regimes are derived from a scaling analysis. The aim of these wall functions is to obtain segregation profiles from purely thermo-hydrodynamic simulations, which do not require solute boundary layer refinement at the solid/liquid interface. Regarding industrial applications, various stirring techniques can be used to enhance segregation, leading to fully turbulent flows in the melt. In this context, the scaling analysis is further improved by taking into account the turbulent solute transport. The solute boundary layers predicted by the analytical model are compared to those obtained by transient segregation simulations in a canonical 2D lid driven cavity configuration for validation purposes. Convective regimes ranging from laminar to fully turbulent are considered. Growth rate and molecular diffusivity influences are also investigated. Then, a procedure to predict concentration fields in the solid phase from a hydrodynamic simulation of the solidification process is proposed. This procedure is based on the analytical wall functions and on solute mass conservation. It only uses wall shear-stress profiles at the solidification front as input data. The 2D analytical concentration fields are directly compared to the results of the complete simulation of segregation in the lid driven cavity configuration. Finally, an additional output from the analytical model is also presented. We put in light the correlation between different species convecto-diffusive behaviour; we use it to propose an estimation method for the segregation parameters of various chemical species knowing segregation parameters of one specific species.

Influence of Pressure Field in Melts on the Primary Nucleation in Solidification Processing

NASA Astrophysics Data System (ADS)

Rakita, Milan; Han, Qingyou

2017-10-01

It is well known that external fields applied to melts can cause nucleation at lower supercoolings, fragmentation of growing dendrites, and forced convection around the solidification front. All these effects contribute to a finer microstructure of solidified material. In this article, we analyze how the pressure field created with ultrasonic vibrations influences structure refinement in terms of supercooling. It is shown that only high cavitation pressures of the order of 104 atmospheres are capable of nucleating crystals at minimal supercoolings. We demonstrate the possibility of sononucleation even in superheated liquid. Simulation and experiments with water samples show that very high cavitation pressures occur in a relatively narrow zone where the drive acoustic field has an appropriate combination of pressure amplitude and frequency. In order to accurately predict the microstructure formed by ultrasonically assisted solidification of metals, this article calls for the development of equations of state that would describe the pressure-dependent behavior of molten metals.

Modelling morphology evolution during solidification of IPP in processing conditions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pantani, R., E-mail: rpantani@unisa.it, E-mail: fedesantis@unisa.it, E-mail: vsperanza@unisa.it, E-mail: gtitomanlio@unisa.it; De Santis, F., E-mail: rpantani@unisa.it, E-mail: fedesantis@unisa.it, E-mail: vsperanza@unisa.it, E-mail: gtitomanlio@unisa.it; Speranza, V., E-mail: rpantani@unisa.it, E-mail: fedesantis@unisa.it, E-mail: vsperanza@unisa.it, E-mail: gtitomanlio@unisa.it

During polymer processing, crystallization takes place during or soon after flow. In most of cases, the flow field dramatically influences both the crystallization kinetics and the crystal morphology. On their turn, crystallinity and morphology affect product properties. Consequently, in the last decade, researchers tried to identify the main parameters determining crystallinity and morphology evolution during solidification In processing conditions. In this work, we present an approach to model flow-induced crystallization with the aim of predicting the morphology after processing. The approach is based on: interpretation of the FIC as the effect of molecular stretch on the thermodynamic crystallization temperature; modelingmore » the molecular stretch evolution by means of a model simple and easy to be implemented in polymer processing simulation codes; identification of the effect of flow on nucleation density and spherulites growth rate by means of simple experiments; determination of the condition under which fibers form instead of spherulites. Model predictions reproduce most of the features of final morphology observed in the samples after solidification.« less

Containerless processing of single crystals in low-G environment

NASA Technical Reports Server (NTRS)

Walter, H. U.

1974-01-01

Experiments on containerless crystal growth from the melt were conducted during Skylab missions SL3 and SL4 (Skylab Experiment M-560). Six samples of InSb were processed, one of them heavily doped with selenium. The concept of the experiment is discussed and related to general crystal growth methods and their merits as techniques for containerless processing in space. The morphology of the crystals obtained is explained in terms of volume changes associated with solidification and wetting conditions during solidification. All samples exhibit extremely well developed growth facets. Analysis by X-ray topographical methods and chemical etching shows that the crystals are of high structural perfection. Average dislocation density as revealed by etching is of the order of 100 per sq cm; no dislocation clusters could be observed in the space-grown samples. A sequence of striations that is observed in the first half of the selenium-doped sample is explained as being caused by periodic surface breakdown.

Breakdown of Burton Prim Slichter approach and lateral solute segregation in radially converging flows

NASA Astrophysics Data System (ADS)

Priede, J.; Gerbeth, G.

2005-11-01

A theoretical study is presented of the effect of a radially converging melt flow, which is directed away from the solidification front, on the radial solute segregation in simple solidification models. We show that the classical Burton-Prim-Slichter (BPS) solution describing the effect of a diverging flow on the solute incorporation into the solidifying material breaks down for the flows converging along the solidification front. The breakdown is caused by a divergence of the integral defining the effective boundary layer thickness which is the basic concept of the BPS theory. Although such a divergence can formally be avoided by restricting the axial extension of the melt to a layer of finite height, radially uniform solute distributions are possible only for weak melt flows with an axial velocity away from the solidification front comparable to the growth rate. There is a critical melt velocity for each growth rate at which the solution passes through a singularity and becomes physically inconsistent for stronger melt flows. To resolve these inconsistencies we consider a solidification front presented by a disk of finite radius R0 subject to a strong converging melt flow and obtain an analytic solution showing that the radial solute concentration depends on the radius r as ˜ln(R0/r) and ˜ln(R0/r) close to the rim and at large distances from it. The logarithmic increase of concentration is limited in the vicinity of the symmetry axis by the diffusion becoming effective at a distance comparable to the characteristic thickness of the solute boundary layer. The converging flow causes a solute pile-up forming a logarithmic concentration peak at the symmetry axis which might be an undesirable feature for crystal growth processes.

[Recent advance in solidification/stabilization technology for the remediation of heavy metals-contaminated soil].

PubMed

Hao, Han-zhou; Chen, Tong-bin; Jin, Meng-gui; Lei, Mei; Liu, Cheng-wu; Zu, Wen-pu; Huang, Li-mi

2011-03-01

Remediation of heavy metals-contaminated soil is still a difficulty and a hotspot of international research projects. At present, the technologies commonly adopted for the remediation of contaminated sites mainly include excavation, solidification/stabilization (S/S), soil washing, soil vapor extraction (SVE), thermal treatment, and bioremediation. Based on the S/S technical guidelines of Unite State Environmental Protection Agency (EPA) and United Kingdom Environment Agency (EA) and the domestic and foreign patents, this paper introduced the concepts of S/S and its development status at home and abroad, and discussed its future development directions. Solidification refers to a process that binds contaminated media with a reagent, changing the media's physical properties via increasing its compressive strength, decreasing its permeability, and encapsulating the contaminants to form a solid material. Stabilization refers to the process that involves a chemical reaction which reduces the leachability of a waste, chemically immobilizes the waste and reduces its solubility, making the waste become less harmful or less mobile. S/S technology includes cement solidification, lime pozzolanic solidification, plastic materials stabilization, vitrification, and regent-based stabilization. Stabilization (or immobilization) treatment processes convert contaminants to less mobile forms through chemical or thermal interactions. In stabilization technology, the aim of adding agents is to change the soil physical and chemical properties through pH control technology, redox potential technology, precipitation techniques, adsorption technology, and ion-exchange technology that change the existing forms of heavy metals in soil, and thus, reduce the heavy metals bioavailability and mobility. This review also discussed the S/S evaluation methods, highlighted the need to enhance S/S technology in the molecular bonding, soil polymers, and formulation of China's S/S technical guidelines.

Undercooling Behavior and Intermetallic Compound Coalescence in Microscale Sn-3.0Ag-0.5Cu Solder Balls and Sn-3.0Ag-0.5Cu/Cu Joints

NASA Astrophysics Data System (ADS)

Zhou, M. B.; Ma, X.; Zhang, X. P.

2012-11-01

The microstructure of microscale solder interconnects and soldering defects have long been known to have a significant influence on the reliability of electronic packaging, and both are directly related to the solidification behavior of the undercooled solder. In this study, the undercooling behavior and solidification microstructural evolution of Sn-3.0Ag-0.5Cu solder balls with different diameters (0.76 mm, 0.50 mm, and 0.30 mm) and the joints formed by soldering these balls on Cu open pads of two diameters (0.48 mm and 0.32 mm) on a printed circuit board (PCB) substrate were characterized by differential scanning calorimetry (DSC) incorporated into the reflow process. Results show that the decrease in diameter of the solder balls leads to an obvious increase in the undercooling of the balls, while the undercooling of the solder joints shows a dependence on both the diameter of the solder balls and the diameter ratio of solder ball to Cu pad (i.e., D s/ D p), and the diameter of the solder balls has a stronger influence on the undercooling of the joints than the dimension of the Cu pad. Coarse primary intermetallic compound (IMC) solidification phases were formed in the smaller solder balls and joints. The bulk Ag3Sn IMC is the primary solidification phase in the as-reflowed solder balls. Due to the interfacial reaction and dissolution of Cu atoms into the solder matrix, the primary Ag3Sn phase can be suppressed and the bulk Cu6Sn5 IMC is the only primary solidification phase in the as-reflowed solder joints.

Optimization of heat transfer during the directional solidification process of 1600 kg silicon feedstock

NASA Astrophysics Data System (ADS)

Hu, Chieh; Chen, Jyh Chen; Nguyen, Thi Hoai Thu; Hou, Zhi Zhong; Chen, Chun Hung; Huang, Yen Hao; Yang, Michael

2018-02-01

In this study, the power ratio between the top and side heaters and the moving velocity of the side insulation are designed to control the shape of the crystal-melt interface during the growth process of a 1600 kg multi-crystalline silicon ingot. The power ratio and insulation gap are adjusted to ensure solidification of the melt. To ensure that the crystal-melt interface is slightly convex in relation to the melt during the entire solidification process, the power ratio should be augmented gradually in the initial stages while being held to a constant value in the middle stages. Initially the gap between the side and the bottom insulation is kept small to reduce thermal stress inside the seed crystals. However, the growth rate will be slow in the early stages of the solidification process. Therefore, the movement of the side insulation is fast in the initial stages but slower in the middle stages. In the later stages, the side insulation gap is fixed. With these modifications, the convexity of the crystal-melt interface in relation to the melt can be maintained during the growth process with an approximately 41% reduction in the thermal stress inside the growing ingot and an 80% reduction in dislocation density along the center line of the ingot compared with the original case.

Hot cracking of Structural Steel during Laser Welding

NASA Astrophysics Data System (ADS)

Pineda Huitron, Rosa M.; Vuorinen, Esa

2017-10-01

Laser welding is an important technique in many industries due to its high precision in operation, its local and fast processing, narrow welds and its good weld surface quality. However, the process can involve some complications due to the rapid heating and cooling of the material processed, resulting in physical and metallurgical effects as thermal contraction during solidification, giving as a result the presence of residual stresses in the narrow weld. Formation of defects during the process is an important topic to be evaluated in order to achieve better performance of the steels in use. In the present work, defects formed during laser welding of a structural steel have been investigated. The defects formed have been identified and the causes of the defects are discussed. Possible strategies for improvement of the welding procedure and final weld result are proposed. The defects were analysed by optical and scanning electron microscopy and hardness measurement. Cracks were located in the middle of the fusion zone and followed both inter-granular and trans-granular paths. Impurities as manganese sulphides were found along the welding direction, and could act as sites for crack formation. The cracks formed during solidification of the weld are identified as solidification cracks. This kind of cracks is usually caused by solidification shrinkage and thermal contractions during the process, which appear in the fusion zone and sometimes in the heat affected zone.

Investigation of microgravity effects on solidification phenomena of selected materials

NASA Technical Reports Server (NTRS)

Maag, Carl R.; Hansen, Patricia A.

1992-01-01

A Get Away Special (GAS) experiment payload to investigate microgravity effects on solidification phenomena of selected experimental samples has been designed for flight. It is intended that the first flight of the assembly will (1) study the p-n junction characteristics for advancing semiconductor device applications, (2) study the effects of gravity-driven convection on the growth of HgCd crystals, (3) compare the textures of the sample which crystallizes in microgravity with those found in chondrite meteorites, and (4) modify glass optical characteristics through divalent oxygen exchange. The space flight experiment consists of many small furnaces. While the experiment payload is in the low gravity environment of orbital flight, the payload controller will sequentially activate the furnaces to heat samples to their melt state and then allow cooling to resolidification in a controlled fashion. The materials processed in the microgravity environment of space will be compared to the same materials processed on earth in a one-gravity environment. This paper discusses the design of all subassemblies (furnance, electronics, and power systems) in the experiment. A complete description of the experimental materials is also presented.

Achiral-to-chiral transition in benzil solidification: analogies with racemic conglomerates systems showing deracemization.

PubMed

El-Hachemi, Zoubir; Arteaga, Oriol; Canillas, Adolf; Crusats, Joaquim; Sorrenti, Alessandro; Veintemillas-Verdaguer, Sabino; Ribo, Josep M

2013-07-01

Experimental results show that benzil (1,2-diphenyl-1,2-ethanedione), an achiral compound that crystallizes as a racemic conglomerate, yields by solidification polycrystalline scalemic mixtures of high enantiomeric excesses. These results are related to those previously reported in this type of compounds on deracemizations of racemic mixtures of crystal enantiomorphs obtained by wet grinding. However, the present results strongly suggest that these experiments cannot be explained without taking into account chiral recognition interactions at the level of precritical clusters. The conditions that would define a general thermodynamic scenario for such deracemizations are discussed. © 2013 Wiley Periodicals, Inc.

Cellular-dendritic transition in directionally solidified binary alloys

NASA Technical Reports Server (NTRS)

Tewari, S. N.; Laxmanan, V.

1987-01-01

The microstructural development of binary alloys during directional solidification is studied. Cellular growth data for the Al-Cu and Pb-Sn binary alloy systems are analyzed in order evaluate the criteria of Kurz and Fisher (1981) and Trivedi (1984) for cellular-dendritic transition. It is observed that the experimental growth values do not correlate with the Kurz and Fisher or Trivedi data.

The effect of growth rate on the compositional variations in directionally solidified Hg(1-x)CdsubxSe

NASA Technical Reports Server (NTRS)

Andrews, R. N.

1986-01-01

Several Hg1-xCdxSe crystals of composition x = 0.2 were grown in a bridgman-type directional solidification furnace at varying translation rates. The influence of growth rate on both the longitudinal and radial compositional uniformity for the crystals was determined using density measurements and infrared transmission-edge mapping.

Crystallization dynamics in glass-forming systems

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cullinan, Timothy Edward

Crystallization under far-from-equilibrium conditions is investigated for two different scenarios: crystallization of the metallic glass alloy Cu 50Zr 50 and solidification of a transparent organic compound, o-terphenyl. For Cu 50Zr 50, crystallization kinetics are quanti ed through a new procedure that directly fits thermal analysis data to the commonly utilized JMAK model. The phase evolution during crystallization is quantified through in-situ measurements (HEXRD, DSC) and ex-situ microstructural analysis (TEM, HRTEM). The influence of chemical partitioning, diffusion, and crystallographic orientation on this sequence are examined. For o-terphenyl, the relationship between crystal growth velocity and interface undercooling is systematically studied via directionalmore » solidification.« less

The effect of gravity modulation on thermosolutal convection

NASA Technical Reports Server (NTRS)

Saunders, Bonita V.; Murray, Bruce T.; Mcfadden, G. B.; Coriell, S. R.; Wheeler, A. A.

1992-01-01

In a gravitational field, the opposing effects of components of different diffusivities, for example, temperature and solute, in the density profile in a fluid may produce convective instabilities that exhibit a broad range of dynamical behavior. The effect of time periodic vertical gravity modulation on the onset of these instabilities in an infinite horizontal layer with stress free boundaries is examined. This work is viewed as a first step in expanding previous results in solidification to the full problem of characterizing the effects of gravity modulation in thermosolutal convection during the directional solidification of binary alloys. Calculations carried out both with and without steady background acceleration are presented, the latter results being relevant to microgravity conditions.

Convection in containerless processing.

PubMed

Hyers, Robert W; Matson, Douglas M; Kelton, Kenneth F; Rogers, Jan R

2004-11-01

Different containerless processing techniques have different strengths and weaknesses. Applying more than one technique allows various parts of a problem to be solved separately. For two research projects, one on phase selection in steels and the other on nucleation and growth of quasicrystals, a combination of experiments using electrostatic levitation (ESL) and electromagnetic levitation (EML) is appropriate. In both experiments, convection is an important variable. The convective conditions achievable with each method are compared for two very different materials: a low-viscosity, high-temperature stainless steel, and a high-viscosity, low-temperature quasicrystal-forming alloy. It is clear that the techniques are complementary when convection is a parameter to be explored in the experiments. For a number of reasons, including the sample size, temperature, and reactivity, direct measurement of the convective velocity is not feasible. Therefore, we must rely on computation techniques to estimate convection in these experiments. These models are an essential part of almost any microgravity investigation. The methods employed and results obtained for the projects levitation observation of dendrite evolution in steel ternary alloy rapid solidification (LODESTARS) and quasicrystalline undercooled alloys for space investigation (QUASI) are explained.

Influence of solidification accelerators on structure formation of anhydrite-containing binders

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anikanova, L., E-mail: alasmit@mail.ru; Volkova, O., E-mail: v.olga.nikitina@gmail.com; Kudyakov, A.

2016-01-15

The article presents results of scientific analysis of chemical additives influence on acid fluoride binder. It was found that the influence of sulfate nature additives on the process of hydration and solidification of the binder is similar to influence of additives on indissoluble anhydrite. Additives with SO{sub 4}{sup 2−} anion NO{sup −} are more efficient. The mentioned additives according to accelerating effect belong to the following succession: K{sub 2}SO{sub 4} > Na{sub 2}SO{sub 4} > FeSO{sub 4} > MgSO{sub 4}. Facilitation of the process of hydration and solidification of the binder, increase in density and durability of the binder (32 MPa)more » is to the greatest extent achieved with the introduction of 2% sodium sulfate additive of the binder’s mass into the composition of the binder along with the ultrasonic treatment of water solution. Directed crystal formation process with healing of porous structure by new growths presented as calcium sulfate dehydrate and hydroglauberite provides positive effect.« less

Delta-Ferrite Distribution in a Continuous Casting Slab of Fe-Cr-Mn Austenitic Stainless Steel

NASA Astrophysics Data System (ADS)

Chen, Chao; Cheng, Guoguang

2017-10-01

The delta-ferrite distribution in a continuous casting slab of Fe-Cr-Mn stainless steel grade (200 series J4) was analyzed. The results showed that the ferrite fraction was less than 3 pct. The "M" type distribution was observed in the thickness direction. For the distribution at the centerline, the maximum ferrite content was found in the triangular zone of the macrostructure. In addition, in this zone, the carbon and sulfur were severely segregated. Furthermore, an equilibrium solidification calculation by Thermo-Calc® software indicates that the solidification mode of the composition in this triangular zone is the same as the solidification mode of the averaged composition, i.e., the FA (ferrite-austenite) mode. None of the nickel-chromium equivalent formulas combined with the Schaeffler-type diagram could predict the ferrite fraction of the Cr-Mn stainless steel grade in a reasonable manner. The authors propose that more attention should be paid to the development of prediction models for the ferrite fraction of stainless steels under continuous casting conditions.

Development of an Optimization Methodology for the Aluminum Alloy Wheel Casting Process

NASA Astrophysics Data System (ADS)

Duan, Jianglan; Reilly, Carl; Maijer, Daan M.; Cockcroft, Steve L.; Phillion, Andre B.

2015-08-01

An optimization methodology has been developed for the aluminum alloy wheel casting process. The methodology is focused on improving the timing of cooling processes in a die to achieve improved casting quality. This methodology utilizes (1) a casting process model, which was developed within the commercial finite element package, ABAQUS™—ABAQUS is a trademark of Dassault Systèms; (2) a Python-based results extraction procedure; and (3) a numerical optimization module from the open-source Python library, Scipy. To achieve optimal casting quality, a set of constraints have been defined to ensure directional solidification, and an objective function, based on the solidification cooling rates, has been defined to either maximize, or target a specific, cooling rate. The methodology has been applied to a series of casting and die geometries with different cooling system configurations, including a 2-D axisymmetric wheel and die assembly generated from a full-scale prototype wheel. The results show that, with properly defined constraint and objective functions, solidification conditions can be improved and optimal cooling conditions can be achieved leading to process productivity and product quality improvements.

Effect of Surface Tension Anisotropy and Welding Parameters on Initial Instability Dynamics During Solidification: A Phase-Field Study

NASA Astrophysics Data System (ADS)

Yu, Fengyi; Wei, Yanhong

2018-05-01

The effects of surface tension anisotropy and welding parameters on initial instability dynamics during gas tungsten arc welding of an Al-alloy are investigated by a quantitative phase-field model. The results show that the surface tension anisotropy and welding parameters affect the initial instability dynamics in different ways during welding. The surface tension anisotropy does not influence the solute diffusion process but does affect the stability of the solid/liquid interface during solidification. The welding parameters affect the initial instability dynamics by varying the growth rate and thermal gradient. The incubation time decreases, and the initial wavelength remains stable as the welding speed increases. When welding power increases, the incubation time increases and the initial wavelength slightly increases. Experiments were performed for the same set of welding parameters used in modeling, and the results of the experiments and simulations were in good agreement.

Columnar and Equiaxed Solidification of Al-7 wt.% Si Alloys in Reduced Gravity in the Framework of the CETSOL Project

NASA Astrophysics Data System (ADS)

Zimmermann, G.; Sturz, L.; Nguyen-Thi, H.; Mangelinck-Noel, N.; Li, Y. Z.; Gandin, C.-A.; Fleurisson, R.; Guillemot, G.; McFadden, S.; Mooney, R. P.; Voorhees, P.; Roosz, A.; Ronaföldi, A.; Beckermann, C.; Karma, A.; Chen, C.-H.; Warnken, N.; Saad, A.; Grün, G.-U.; Grohn, M.; Poitrault, I.; Pehl, T.; Nagy, I.; Todt, D.; Minster, O.; Sillekens, W.

2017-08-01

During casting, often a dendritic microstructure is formed, resulting in a columnar or an equiaxed grain structure, or leading to a transition from columnar to equiaxed growth (CET). The detailed knowledge of the critical parameters for the CET is important because the microstructure affects materials properties. To provide unique data for testing of fundamental theories of grain and microstructure formation, solidification experiments in microgravity environment were performed within the European Space Agency Microgravity Application Promotion (ESA MAP) project Columnar-to-Equiaxed Transition in SOLidification Processing (CETSOL). Reduced gravity allows for purely diffusive solidification conditions, i.e., suppressing melt flow and sedimentation and floatation effects. On-board the International Space Station, Al-7 wt.% Si alloys with and without grain refiners were solidified in different temperature gradients and with different cooling conditions. Detailed analysis of the microstructure and the grain structure showed purely columnar growth for nonrefined alloys. The CET was detected only for refined alloys, either as a sharp CET in the case of a sudden increase in the solidification velocity or as a progressive CET in the case of a continuous decrease of the temperature gradient. The present experimental data were used for numerical modeling of the CET with three different approaches: (1) a front tracking model using an equiaxed growth model, (2) a three-dimensional (3D) cellular automaton-finite element model, and (3) a 3D dendrite needle network method. Each model allows for predicting the columnar dendrite tip undercooling and the growth rate with respect to time. Furthermore, the positions of CET and the spatial extent of the CET, being sharp or progressive, are in reasonably good quantitative agreement with experimental measurements.

Fundamentals of Mold Free Casting: Experimental and Computational Studies

NASA Technical Reports Server (NTRS)

Tryggvason, Gretar; Ceccio, Steven

1997-01-01

Researchers are developing the technology of 'Ballistic Particle Manufacturing' (BPM) in which individual drops are precisely layered onto a substrate, and the drops are deposited so as to prevent splatting. These individual drops will ultimately be combined to form a net-shape, three-dimensional object. Our understanding of controlled drop deposition as applied to BPM is far from complete. Process parameters include the size and temperature of the liquid metal drop, its impact velocity and trajectory, and the condition and temperature of the substrate. Quantitative knowledge of the fluid mechanics and heat transfer of drop deposition and solidification are necessary to fully optimize the manufacturing process and to control the material microstructure of the final part. The object of this study is to examine the dynamics of liquid metal drops as they impinge upon a solid surface and solidify under conditions consistent with BPM (i.e. conditions which produce non-splatting drops). A program of both numerical simulations and experiments will be conducted. Questions this study will address include the following: How do the deformation and solidification of the drop depend on the properties of the fluid drop and the solid substrate? How does the presence of previously deposited drops affect the impingement and solidification process? How does the impingement of the new drop affect already deposited material? How does the cooling rate and solidification of the drops influence the material microstructure?

High temperature composites. Status and future directions

NASA Technical Reports Server (NTRS)

Signorelli, R. A.

1982-01-01

A summary of research investigations of manufacturing methods, fabrication methods, and testing of high temperature composites for use in gas turbine engines is presented. Ceramic/ceramic, ceramic/metal, and metal/metal composites are considered. Directional solidification of superalloys and eutectic alloys, fiber reinforced metal and ceramic composites, ceramic fibers and whiskers, refractory coatings, metal fiber/metal composites, matrix metal selection, and the preparation of test specimens are discussed.

On the Role of Mantle Overturn during Magma Ocean Solidification

NASA Astrophysics Data System (ADS)

Boukaré, C. E.; Parmentier, E.; Parman, S. W.

2017-12-01

Solidification of potential global magma ocean(s) (MO) early in the history of terrestrial planets may play a key role in the evolution of planetary interiors by setting initial conditions for their long-term evolution. Constraining this initial structure of solid mantles is thus crucial but remains poorly understood. MO fractional crystallization has been proposed to generate gravitationally unstable Fe-Mg chemical stratification capable of driving solid-state mantle overturn. Fractional solidification and overturn hypothesis, while only an ideal limiting case, can explain important geochemical features of both the Moon and Mars. Current overturn models consider generally post-MO overturn where the cumulate pile remains immobile until the end of MO solidification. However, if the cumulate pile overturns during MO solidification, the general picture of early planet evolution might differ significantly from the static crystallization models. We show that the timing of mantle overturn can be characterized with a dimensionless number measuring the ratio of the MO solidification time and the purely compositional overturn timescale. Syn-solidification overturn occurs if this dimensionless parameter, Rc, exceeds a critical value. Rc is mostly affected by the competition between the MO solidification time and mantle viscosity. Overturn that occurs during solidification can result in smaller scales of mantle chemical heterogeneity that could persist for long times thus influencing the whole evolution of a planetary body. We will discuss the effects of compaction/percolation on mantle viscosity. If partially molten cumulate do not have time to compact during MO solidification, viscosity of cumulates would be significantly lower as the interstitcial melt fraction would be large. Both solid mantle remelting during syn-solidification overturn and porous convection of melt retained with the cumulates are expected to reduce the degree of fractional crystallization. Syn-solidification overturn of a sluggish mantle can thus be an alternative to solid-state post-MO solidification overturn.

Relationships Between Solidification Parameters in A319 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Vandersluis, E.; Ravindran, C.

2018-03-01

The design of high-performance materials depends on a comprehensive understanding of the alloy-specific relationships between solidification and properties. However, the inconsistent use of a particular solidification parameter for presenting materials characterization in the literature impedes inter-study comparability and the interpretation of findings. Therefore, there is a need for accurate expressions relating the solidification parameters for each alloy. In this study, A319 aluminum alloy castings were produced in a permanent mold with various preheating temperatures in order to control metal cooling. Analysis of the cooling curve for each casting enabled the identification of its liquidus, Al-Si eutectic, and solidus temperatures and times. These values led to the calculation of the primary solidification rate, total solidification rate, primary solidification time, and local solidification time for each casting, which were related to each other as well as to the average casting SDAS and material hardness. Expressions for each of their correlations have been presented with high coefficients of determination, which will aid in microstructural prediction and casting design.

Simulation of Laser Additive Manufacturing and its Applications

NASA Astrophysics Data System (ADS)

Lee, Yousub

Laser and metal powder based additive manufacturing (AM), a key category of advanced Direct Digital Manufacturing (DDM), produces metallic components directly from a digital representation of the part such as a CAD file. It is well suited for the production of high-value, customizable components with complex geometry and the repair of damaged components. Currently, the main challenges for laser and metal powder based AM include the formation of defects (e.g., porosity), low surface finish quality, and spatially non-uniform properties of material. Such challenges stem largely from the limited knowledge of complex physical processes in AM especially the molten pool physics such as melting, molten metal flow, heat conduction, vaporization of alloying elements, and solidification. Direct experimental measurement of melt pool phenomena is highly difficult since the process is localized (on the order of 0.1 mm to 1 mm melt pool size) and transient (on the order of 1 m/s scanning speed). Furthermore, current optical and infrared cameras are limited to observe the melt pool surface. As a result, fluid flows in the melt pool, melt pool shape and formation of sub-surface defects are difficult to be visualized by experiment. On the other hand, numerical simulation, based on rigorous solution of mass, momentum and energy transport equations, can provide important quantitative knowledge of complex transport phenomena taking place in AM. The overarching goal of this dissertation research is to develop an analytical foundation for fundamental understanding of heat transfer, molten metal flow and free surface evolution. Two key types of laser AM processes are studied: a) powder injection, commonly used for repairing of turbine blades, and b) powder bed, commonly used for manufacturing of new parts with complex geometry. In the powder injection simulation, fluid convection, temperature gradient (G), solidification rate (R) and melt pool shape are calculated using a heat transfer and fluid flow model, which solves the mass, momentum and energy transport equations using the volume of fluid (VOF) method. These results provide quantitative understanding of underlying mechanisms of solidification morphology, solidification scale and deposit side bulging. In particular, it is shown that convective mixing alters solidification conditions (G and R), cooling trend and resultant size of primary dendrite arm spacing. Melt pool convexity in multiple layer LAM is associated not only with the convex shape of prior deposit but also with Marangoni flow. Lastly, it is shown that the lateral width of bulge is possibly controlled by the type of surface tension gradient. It is noted that laser beam spot size in the powder injection AM is about 2 mm and it melts hundreds of powder particles. Hence, the injection of individual particles is approximated by a lumped mass flux into the molten pool. On the other hand, for laser powder bed AM, the laser beam spot size is about 100 microm and thus it only melts a few tens of particles. Therefore, resolution of individual powder particles is essential for the accurate simulation of laser powder bed AM. To obtain the powder packing information in the powder bed, dynamic discrete element simulation (DEM) is used. It considers particle-particle interactions during packing to provide the quantitative structural powder bed properties such as particle arrangement, size and packing density, which is then an inputted as initial geometry for heat transfer and fluid flow simulation. This coupled 3D transient transport model provides a high spatial resolution while requiring less demanding computation. The results show that negatively skewed particle size distribution, faster scanning speed, low power and low packing density worsen the surface finish quality and promote the formation of balling defects. Taken together, both powder injection and powder bed models have resulted in an improved quantitative understanding of heat transfer, molten metal flow and free surface evolution. Furthermore, the analytical foundation that is developed in this dissertation provides the temperature history in AM, a prerequisite for predicting the solid-state phase transformation kinetics, residual stresses and distortion using other models. Moreover, it can be integrated with experimental monitoring and sensing tools to provide the capability of controlling melt pool shape, solidification microstructure, defect formation and surface finish.

Role of Dynamic Nucleation at Moving Boundaries in Phase and Microstructure Selection

NASA Technical Reports Server (NTRS)

Karma, Alain; Trivedi, Rohit

1999-01-01

Solidification microstructures that form under steady-state growth conditions (cells, dendrites, regular eutectics, etc.) are reasonably well understood in comparison to other, more complex microstructures, which form under intrinsically non-steady-state growth conditions due to the competition between the nucleation and growth of several phases. Some important practical examples in this latter class include microstructures forming in peritectic systems in highly undercooled droplets, and in strip cast stainless steels. Prediction of phase and microstructure selection in these systems has been traditionally based on (1) heterogeneous nucleation on a static interface, and (2) comparing the relative growth rate of different phase/microstructures under steady-state growth conditions. The formation of new phases, however, occurs via nucleation on, or ahead of, a moving boundary. In addition, the actual selection process is controlled by a complex interaction between the nucleation process and the growth competition between the nuclei and the pre-existing phase under non-steady-state conditions. As a result, it is often difficult to predict which microstructure will form and which phases will be selected under prescribed processing conditions. This research addresses this critical role of nucleation at moving boundaries in the selection of phases and solidification microstructures through quantitative experiments and numerical modeling in peritectic systems. In order to create a well characterized system in which to study this problem, we focus on the directional solidification of hypo- and hyper-peritectic alloys in the two-phase region, imposing a large enough ratio of temperature gradient/growth rate (G/V(sub p)) to suppress the morphological instability of both the parent (alpha) and peritectic (Beta) phases, i.e. each phase alone would grow as a planar front. Our combined experimental and theoretical results show that, already in this simplified case, the growth competition of these two phases leads to a rich variety of microstructures that depend sensitively upon the relative importance of nucleation, diffusion, and convection.

EFFECT OF PRE-ALLOYING CONDITION ON THE BULK AMORPHOUS ALLOY ND(60)FE(30)AL(10).

DOE Office of Scientific and Technical Information (OSTI.GOV)

OCONNOR,A.S.; LEWIS,L.H.; MCCALLUM,R.W.

Bulk metallic glasses are materials that require only modest cooling rates to obtain amorphous solids directly from the melt. Nd{sub 60}Fe{sub 30}Al{sub 10} has been reported to be a ferromagnetic bulk metallic glass that exhibits high coercivity, a combination unlike conventional Nd-based amorphous magnetic alloys. To clarify the relationship between short-range order and high coercivity in glassy Nd{sub 60}Fe{sub 30}Al{sub 10}, experiments were performed to verify the existence of a homogeneous liquid state prior to rapid solidification. Alloys were prepared by various pre-alloying routes and then melt-spun. Arc-melted alloys were prepared for melt spinning using three different protocols involving: (1)more » alloying all three elements at once, (2) forming a Nd-Fe alloy which was subsequently alloyed with Al, and (3) forming a Fe-Al alloy for subsequent alloying with Nd. XRD, DTA, and magnetic measurement data from the resultant ribbons indicate significant differences in both the glassy fraction and the crystalline phase present in the as-spun material. These observed differences are attributed to the presence of highly stable nanoscopic aluminide-and/or silicide-phases, or motes, present in the melt prior to solidification. These motes would affect the short-range order and coercivity of the resultant glassy state and are anticipated to provide heterogeneous nucleation sites for crystallization.« less

Effects of Undercooling and Cooling Rate on Peritectic Phase Crystallization Within Ni-Zr Alloy Melt

NASA Astrophysics Data System (ADS)

Lü, P.; Wang, H. P.

2018-04-01

The liquid Ni-16.75 at. pct Zr peritectic alloy was substantially undercooled and containerlessly solidified by an electromagnetic levitator and a drop tube. The dependence of the peritectic solidification mode on undercooling was established based on the results of the solidified microstructures, crystal growth velocity, as well as X-ray diffraction patterns. Below a critical undercooling of 124 K, the primary Ni7Zr2 phase preferentially nucleates and grows from the undercooled liquid, which is followed by a peritectic reaction of Ni7Zr2+L → Ni5Zr. The corresponding microstructure is composed of the Ni7Zr2 dendrites, peritectic Ni5Zr phase, and inter-dendritic eutectic. Nevertheless, once the liquid undercooling exceeds the critical undercooling, the peritectic Ni5Zr phase directly precipitates from this undercooled liquid. However, a negligible amount of residual Ni7Zr2 phase still appears in the microstructure, indicating that nucleation and growth of the Ni7Zr2 phase are not completely suppressed. The micromechanical property of the peritectic Ni5Zr phase in terms of the Vickers microhardness is enhanced, which is ascribed to the transition of the peritectic solidification mode. To suppress the formation of the primary phase completely, this alloy was also containerlessly solidified in free fall experiments. Typical peritectic solidified microstructure forms in large droplets, while only the peritectic Ni5Zr phase appears in smaller droplets, which gives an indication that the peritectic Ni5Zr phase directly precipitates from the undercooled liquid by completely suppressing the growth of the primary Ni7Zr2 phase and the peritectic reaction due to the combined effects of the large undercooling and high cooling rate.

Instabilities in rapid directional solidification under weak flow

NASA Astrophysics Data System (ADS)

Kowal, Katarzyna N.; Davis, Stephen H.; Voorhees, Peter W.

2017-12-01

We examine a rapidly solidifying binary alloy under directional solidification with nonequilibrium interfacial thermodynamics viz. the segregation coefficient and the liquidus slope are speed dependent and attachment-kinetic effects are present. Both of these effects alone give rise to (steady) cellular instabilities, mode S , and a pulsatile instability, mode P . We examine how weak imposed boundary-layer flow of magnitude |V | affects these instabilities. For small |V | , mode S becomes a traveling and the flow stabilizes (destabilizes) the interface for small (large) surface energies. For small |V | , mode P has a critical wave number that shifts from zero to nonzero giving spatial structure. The flow promotes this instability and the frequencies of the complex conjugate pairs each increase (decrease) with flow for large (small) wave numbers. These results are obtained by regular perturbation theory in powers of V far from the point where the neutral curves cross, but requires a modified expansion in powers of V1 /3 near the crossing. A uniform composite expansion is then obtained valid for all small |V | .

Effects of physical parameters on the cell-to-dendrite transition in directional solidification

NASA Astrophysics Data System (ADS)

Wei, Lei; Lin, Xin; Wang, Meng; Huang, Wei-Dong

2015-07-01

A quantitative cellular automaton model is used to study the cell-to-dendrite transition (CDT) in directional solidification. We give a detailed description of the CDT by carefully examining the influence of the physical parameters, including: the Gibbs-Thomson coefficient Γ, the solute diffusivity Dl, the solute partition coefficient k0, and the liquidus slope ml. It is found that most of the parameters agree with the Kurz and Fisher (KF) criterion, except for k0. The intrinsic relations among the critical velocity Vcd, the cellular primary spacing λc,max, and the critical spacing λcd are investigated. Project supported by the National Natural Science Foundation of China (Grant Nos. 51271213 and 51323008), the National Basic Research Program of China (Grant No. 2011CB610402), the National High Technology Research and Development Program of China (Grant No. 2013AA031103), the Specialized Research Fund for the Doctoral Program of Higher Education of China (Grant No. 20116102110016), and the China Postdoctoral Science Foundation (Grant No. 2013M540771).

Surface Structure Formation in Direct Chill (DC) Casting of Al Alloys

NASA Astrophysics Data System (ADS)

Bayat, Nazlin; Carlberg, Torbjörn

2014-05-01

The aim of this study is to increase the understanding of the surface zone formation during direct chill (DC) casting of aluminum billets produced by the air slip technology. The depth of the shell zone, with compositions deviating from the bulk, is of large importance for the subsequent extrusion productivity and quality of final products. The surface microstructures of 6060 and 6005 aluminum alloys in three different surface appearances—defect free, wavy surface, and spot defects—were studied. The surface microstructures and outer appearance, segregation depth, and phase formation were investigated for the mentioned cases. The results were discussed and explained based on the exudation of liquid metal through the mushy zone and the fact that the exudated liquid is contained within a surface oxide skin. Outward solidification in the surface layer was quantitatively analyzed, and the oxide skin movements explained meniscus line formation. Phases forming at different positions in the segregation zone were analyzed and coupled to a cellular solidification in the exudated layer.

Directional Solidification of a Binary Alloy into a Cellular Convective Flow: Localized Morphologies

NASA Technical Reports Server (NTRS)

Chen, Y.- J.; Davis, S. H.

1999-01-01

A steady, two dimensional cellular convection modifies the morphological instability of a binary alloy that undergoes directional solidification. When the convection wavelength is far longer than that of the morphological cells, the behavior of the moving front is described by a slow, spatial-temporal dynamics obtained through a multiple-scale analysis. The resulting system has a "parametric-excitation" structure in space, with complex parameters characterizing the interactions between flow, solute diffusion, and rejection. The convection stabilizes two dimensional disturbances oriented with the flow, but destabilizes three dimensional disturbances in general. When the flow is weak, the morphological instability behaves incommensurably to the flow wavelength, but becomes quantized and forced to fit into the flow-box as the flow gets stronger. At large flow magnitudes the instability is localized, confined in narrow envelopes with cells traveling with the flow. In this case the solutions are discrete eigenstates in an unbounded space. Their stability boundary and asymptotics are obtained by the WKB analysis.

The Faceted Discrete Growth and Phase Differentiation During the Directional Solidification of 20SiMnMo5 Steel

NASA Astrophysics Data System (ADS)

Ma, Xiaoping; Li, Dianzhong

2018-07-01

The microstructures, segregation and cooling curve were investigated in the directional solidification of 20SiMnMo5 steel. The typical characteristic of faceted growth is identified. The microstructures within the single cellular and within the single dendritic arm, together with the contradictive segregation distribution against the cooling curve, verify the discrete crystal growth in multi-scales. Not only the single cellular/dendritic arm but also the single martensite zone within the single cellular/dendritic arm is produced by the discrete growth. In the viewpoint of segregation, the basic domain following continuous growth has not been revealed. Along with the multi-scale faceted discrete growth, the phase differentiation happens for both the solid and liquid. The differentiated liquid phases appear and evolve with different sizes, positions, compositions and durations. The physical mechanism for the faceted discrete growth is qualitatively established based on the nucleation of new faceted steps induced by the composition gradient and temperature gradient.

Direct Cast U-6Nb – 2017 Progress on Cylindrical Castings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Aikin, Jr., Robert M.

2017-10-04

This report describes work to further develop a sound technical basis and best practices for mold design and process parameters for the Direct Casting of U-6wt%Nb components. One major challenge to the production of U-6Nb components is the propensity for niobium segregation during casting and solidification. This is especially true for cylindrical castings where the vertical side walls allow flotation of Nb resulting in severe inverse macrosegregation. In this work, a small (120 mm diameter by 180 mm tall) and large cylinder (250 mm diameter by 310 mm tall) are examined with a focus on reducing, or eliminating, niobium segregation.more » It is demonstrated that counter gravity casting (top-to-bottom solidification) can be used to minimize segregation in the small cylinder. Attempts to counter gravity cast the large cylinder were unsuccessful, in large part due to size limitations of the current furnace. A path forward for casting of the large cylinders is discussed.« less

The Faceted Discrete Growth and Phase Differentiation During the Directional Solidification of 20SiMnMo5 Steel

NASA Astrophysics Data System (ADS)

Ma, Xiaoping; Li, Dianzhong

2018-03-01

The microstructures, segregation and cooling curve were investigated in the directional solidification of 20SiMnMo5 steel. The typical characteristic of faceted growth is identified. The microstructures within the single cellular and within the single dendritic arm, together with the contradictive segregation distribution against the cooling curve, verify the discrete crystal growth in multi-scales. Not only the single cellular/dendritic arm but also the single martensite zone within the single cellular/dendritic arm is produced by the discrete growth. In the viewpoint of segregation, the basic domain following continuous growth has not been revealed. Along with the multi-scale faceted discrete growth, the phase differentiation happens for both the solid and liquid. The differentiated liquid phases appear and evolve with different sizes, positions, compositions and durations. The physical mechanism for the faceted discrete growth is qualitatively established based on the nucleation of new faceted steps induced by the composition gradient and temperature gradient.

Numerical study of melt flow under the influence of heater-generating magnetic field during directional solidification of silicon ingots

NASA Astrophysics Data System (ADS)

Li, Zaoyang; Qi, Xiaofang; Liu, Lijun; Zhou, Genshu

2018-02-01

The alternating current (AC) in the resistance heater for generating heating power can induce a magnetic field in the silicon melt during directional solidification (DS) of silicon ingots. We numerically study the influence of such a heater-generating magnetic field on the silicon melt flow and temperature distribution in an industrial DS process. 3D simulations are carried out to calculate the Lorentz force distribution as well as the melt flow and heat transfer in the entire DS furnace. The pattern and intensity of silicon melt flow as well as the temperature distribution are compared for cases with and without Lorentz force. The results show that the Lorentz force induced by the heater-generating magnetic field is mainly distributed near the top and side surfaces of the silicon melt. The melt flow and temperature distribution, especially those in the upper part of the silicon region, can be influenced significantly by the magnetic field.

Welding Behavior of Free Machining Stainless Steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

BROOKS,JOHN A.; ROBINO,CHARLES V.; HEADLEY,THOMAS J.

2000-07-24

The weld solidification and cracking behavior of sulfur bearing free machining austenitic stainless steel was investigated for both gas-tungsten arc (GTA) and pulsed laser beam weld processes. The GTA weld solidification was consistent with those predicted with existing solidification diagrams and the cracking response was controlled primarily by solidification mode. The solidification behavior of the pulsed laser welds was complex, and often contained regions of primary ferrite and primary austenite solidification, although in all cases the welds were found to be completely austenite at room temperature. Electron backscattered diffraction (EBSD) pattern analysis indicated that the nature of the base metalmore » at the time of solidification plays a primary role in initial solidification. The solid state transformation of austenite to ferrite at the fusion zone boundary, and ferrite to austenite on cooling may both be massive in nature. A range of alloy compositions that exhibited good resistance to solidification cracking and was compatible with both welding processes was identified. The compositional range is bounded by laser weldability at lower Cr{sub eq}/Ni{sub eq} ratios and by the GTA weldability at higher ratios. It was found with both processes that the limiting ratios were somewhat dependent upon sulfur content.« less

The effects of gravity level during directional solidification on the microstructure of hypermonotectic Al-In-Sn alloys

NASA Technical Reports Server (NTRS)

Curreri, P. A.; Kaukler, W. F.

1986-01-01

Five hypermonotectic Al-In-Sn compositions were directionally solidified in a Bridgman-type furnace at normal gravity and during aircraft low-gravity maneuvers. The tendency of the Al-30In alloy to form an indium-rich band at the start of unidirectional growth (SUG) made it difficult to study the integration of L sub 2 into the solidification interface. Hypermonotectic compositions closer to monotectic slightly hypermonotectic caused only a partial band on L sub 2 to form at SUG and allowed the study of such variables as gravity, composition, and monotectic dome height on integration of excess L sub 2 into the solid plus L sub 2 interface. It was found that formation of aligned composite structures for the Al-In-Sn system is not only a function of G and R but also of the degree to which the composition varies from monotectic. Most of the aligned fibrous structures formed from hypermonotectic Al-In-Sn had spacings that were of the order of irregular fibrous structures reported for on monotectic Al-In-Sn. The spacings for the large fibers and aligned globules found for ground and low-gravity processed Al-In-18-Sn-22, respectively, were significantly larger than the others measured and were of the order expected for cell spacings under the growth conditions utilized. It was found that the integration into the solidification front of excess L sub 2 in low gravity was a function of the Sn composition of the alloy.

Determination for the Entrapment Criterion of Non-metallic Inclusions by the Solidification Front During Steel Centrifugal Continuous Casting

NASA Astrophysics Data System (ADS)

Wang, Qiangqiang; Zhang, Lifeng

2016-06-01

In the current study, the three-dimensional fluid flow, heat transfer, and solidification in steel centrifugal continuous casting strands were simulated. The volume of fluid model was used to solve the multiphase phenomena between the molten steel and the air. The entrapment and final distribution of inclusions in the solidified shell were studied with the discussion on the effect of rotation behavior of the caster system. Main results indicate that after applying the rotation of the shell, the fluid flow transformed from a recirculation flow to a rotation flow in the mold region and was driven to flow around in the casting direction. As the distance below the meniscus increased, the distribution of the tangential speed of the flow and the centrifugal force along one diameter of the strand became symmetrical gradually. The jet flow from the nozzle hardly impinged on the same location on the shell due to the rotation of the shell during solidification. Thus, the shell thickness on the same height was uniform around, and the thinning shell and a hot spot on the surface of shell were avoided. Both of the measurement and the calculation about the distribution of oxide inclusions along the radial direction indicated the number of inclusions at the side and the center was more than that at the quarter on the cross section of billet. With a larger diameter, inclusions tended to be entrapped toward the center area of the billet.

A model for the influence of pressure on the bulk modulus and the influence of temperature on the solidification pressure for liquid lubricants

NASA Technical Reports Server (NTRS)

Jacobson, B. O.; Vinet, P.

1986-01-01

Two pressure chambers, for compression experiments with liquids from zero to 2.2 GPa pressure, are described. The experimentally measured compressions are then compared to theoretical values given by an isothermal model of equation of state recently introduced for solids. The model describes the pressure and bulk modulus as a function of compression for different types of lubricants with a very high accuracy up to the pressure limit of the high pressure chamber used (2.2 GPa). In addition the influence of temperature on static solidification pressure was found to be a simple function of the thermal expansion of the fluid.

Dual-scale phase-field simulation of Mg-Al alloy solidification

NASA Astrophysics Data System (ADS)

Monas, A.; Shchyglo, O.; Höche, D.; Tegeler, M.; Steinbach, I.

2015-06-01

Phase-field simulations of the nucleation and growth of primary α-Mg phase as well as secondary, β-phase of a Mg-Al alloy are presented. The nucleation model for α- and β-Mg phases is based on the “free growth model” by Greer et al.. After the α-Mg phase solidification we study a divorced eutectic growth of α- and β-Mg phases in a zoomed in melt channel between α-phase dendrites. The simulated cooling curves and final microstructures of α-grains are compared with experiments. In order to further enhance the resolution of the interdendritic region a high-performance computing approach has been used allowing significant simulation speed gain when using supercomputing facilities.

Study of Fluid Experiment System (FES)/CAST/Holographic Ground System (HGS)

NASA Technical Reports Server (NTRS)

Workman, Gary L.; Cummings, Rick; Jones, Brian

1992-01-01

The use of holographic and schlieren optical techniques for studying the concentration gradients in solidification processes has been used by several investigators over the years. The HGS facility at MSFC has been primary resource in researching this capability. Consequently, scientific personnel have been able to utilize these techniques in both ground based research and in space experiments. An important event in the scientific utilization of the HGS facilities was the TGS Crystal Growth and the casting and solidification technology (CAST) experiments that were flown on the International Microgravity Laboratory (IML) mission in March of this year. The preparation and processing of these space observations are the primary experiments reported in this work. This project provides some ground-based studies to optimize on the holographic techniques used to acquire information about the crystal growth processes flown on IML. Since the ground-based studies will be compared with the space-based experimental results, it is necessary to conduct sufficient ground based studies to best determine how the experiment worked in space. The current capabilities in computer based systems for image processing and numerical computation have certainly assisted in those efforts. As anticipated, this study has certainly shown that these advanced computing capabilities are helpful in the data analysis of such experiments.

Laser weldability of 21Cr-6Ni-9Mn stainless steel: Part II - Weldability diagrams

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tate, Stephen B.; Javernick, Daniel Anthony; Lienert, Thomas J.

In this second part of the study, weldability diagrams developed to relate solidification crack susceptibility and chemical composition for laser welded type 21Cr-6Ni-9Mn (21-6-9) stainless steel are presented. Sigmajig testing on 14 commercial 21-6-9 alloys, 20 experimental 21-6-9 alloys, and 7 other high-N, high-Mn austenitic stainless steels was used to develop weldability diagrams for solidification crack susceptibility for laser welding of type 21-6-9. Three travel speeds were used to show the changes in minimum Cr eq/Ni eq for primary ferrite solidification as solidification rate increase d with travel speed . Primary austenite solidification was observed below 1.55 Cr eq/Ni eqmore » (Espy equivalents) at 21 mm/s travel speed. At 42 mm/s travel speed , a mix of solidification modes were displayed for alloys from 1.55-1.75 Cr eq/Ni eq. Primary ferrite solidification was observed above 1.75 Cr eq/Ni eq at both 42 and 85 mm/s travel speeds. No solidification cracking was observed for alloys with primary ferrite solidification. Lastly, variable cracking behavior was found in alloys with primary austenite solidification, but in general cracking was observed in alloys with greater than 0.02 wt-% combined impurity content according to (P+0.2S).« less

Laser weldability of 21Cr-6Ni-9Mn stainless steel: Part II - Weldability diagrams

DOE PAGES

Tate, Stephen B.; Javernick, Daniel Anthony; Lienert, Thomas J.; ...

2016-11-02

In this second part of the study, weldability diagrams developed to relate solidification crack susceptibility and chemical composition for laser welded type 21Cr-6Ni-9Mn (21-6-9) stainless steel are presented. Sigmajig testing on 14 commercial 21-6-9 alloys, 20 experimental 21-6-9 alloys, and 7 other high-N, high-Mn austenitic stainless steels was used to develop weldability diagrams for solidification crack susceptibility for laser welding of type 21-6-9. Three travel speeds were used to show the changes in minimum Cr eq/Ni eq for primary ferrite solidification as solidification rate increase d with travel speed . Primary austenite solidification was observed below 1.55 Cr eq/Ni eqmore » (Espy equivalents) at 21 mm/s travel speed. At 42 mm/s travel speed , a mix of solidification modes were displayed for alloys from 1.55-1.75 Cr eq/Ni eq. Primary ferrite solidification was observed above 1.75 Cr eq/Ni eq at both 42 and 85 mm/s travel speeds. No solidification cracking was observed for alloys with primary ferrite solidification. Lastly, variable cracking behavior was found in alloys with primary austenite solidification, but in general cracking was observed in alloys with greater than 0.02 wt-% combined impurity content according to (P+0.2S).« less

Undercooling, Liquid Separation and Solidification of Cu-Co Alloys

NASA Technical Reports Server (NTRS)

Robinson, M. B.; Li, D.; Rathz, J.; Williams, G.

1998-01-01

Large undercooling can induce not only various solidification pathways, but also a precursor reaction, or liquid separation. This paper deals with the latter effect of undercooling using examples of the Cu-Co system which has a flattened liquidus. Bulk Cu-Co alloys (about 7mm diameter) at compositions ranging from 10 to 90 wt pct Co were highly undercooled using a fluxing technique. Except for Cu-90 wt pct Co, liquid separation was directly observed as undercooling exceeded a critical value depending on the composition. It was also confirmed by a microstructural transition from dendrites to droplets above the critical undercooling. Finally, theoretical calculations regarding the metastable miscibility boundary and maximum droplet radius were made to analyze the experimental results.

Study of the production of some superconducting and magnetic materials by solidification in the drop tube and drop tower

NASA Technical Reports Server (NTRS)

Wu, M. K.

1987-01-01

A systematic study on the relationship between the microstructure and physical properties of several superconducting materials prepared by solidification in low gravity was conducted. Further study of the materials, such as the applications of hydrostatic pressure which is known to be an effective mean to vary the electronic structure of materials, in conjunction with the detailed microstructure analysis of the samples was also performed to better understand the low gravity effects on the enhancement of the electronic properties. Results of the studies on the directionally solidified AlInSn alloys processed in the KC-135 aircraft and immiscible GaBi alloy prepared during free fall in the Marshall Space Flight Center Drop Tower are presented.

Solidification Sequence of Spray-Formed Steels

NASA Astrophysics Data System (ADS)

Zepon, Guilherme; Ellendt, Nils; Uhlenwinkel, Volker; Bolfarini, Claudemiro

2016-02-01

Solidification in spray-forming is still an open discussion in the atomization and deposition area. This paper proposes a solidification model based on the equilibrium solidification path of alloys. The main assumptions of the model are that the deposition zone temperature must be above the alloy's solidus temperature and that the equilibrium liquid fraction at this temperature is reached, which involves partial remelting and/or redissolution of completely solidified droplets. When the deposition zone is cooled, solidification of the remaining liquid takes place under near equilibrium conditions. Scanning electron microscopy (SEM) and optical microscopy (OM) were used to analyze the microstructures of two different spray-formed steel grades: (1) boron modified supermartensitic stainless steel (SMSS) and (2) D2 tool steel. The microstructures were analyzed to determine the sequence of phase formation during solidification. In both cases, the solidification model proposed was validated.

Incorporation of fragmentation into a volume average solidification model

NASA Astrophysics Data System (ADS)

Zheng, Y.; Wu, M.; Kharicha, A.; Ludwig, A.

2018-01-01

In this study, a volume average solidification model was extended to consider fragmentation as a source of equiaxed crystals during mixed columnar-equiaxed solidification. The formulation suggested for fragmentation is based on two hypotheses: the solute-driven remelting is the dominant mechanism; and the transport of solute-enriched melt through an interdendritic flow in the columnar growth direction is favorable for solute-driven remelting and is the necessary condition for fragment transportation. Furthermore, a test case with Sn-10 wt%Pb melt solidifying vertically downward in a 2D domain (50 × 60 mm2) was calculated to demonstrate the model’s features. Solidification started from the top boundary, and a columnar structure developed initially with its tip growing downward. Furthermore, thermo-solutal convection led to fragmentation in the mushy zone near the columnar tip front. The fragments transported out of the columnar region continued to grow and sink, and finally settled down and piled up in the bottom domain. The growing columnar structure from the top and pile-up of equiaxed crystals from the bottom finally led to a mixed columnar-equiaxed structure, in turn leading to a columnar-to-equiaxed transition (CET). A special macrosegregation pattern was also predicted, in which negative segregation occurred in both columnar and equiaxed regions and a relatively strong positive segregation occurred in the middle domain near the CET line. A parameter study was performed to verify the model capability, and the uncertainty of the model assumption and parameter was discussed.

Effects of high pressure on microstructure evolution and crystallization mechanisms during solidification of nickel

NASA Astrophysics Data System (ADS)

Zhang, Hai-Tao; Mo, Yun-Fei; Liu, Rang-Su; Tian, Ze-An; Liu, Hai-Rong; Hou, Zhao-Yang; Zhou, Li-Li; Liang, Yong-Chao; Peng, Ping

2018-03-01

To deeply understand the effects of high pressure on microstructural evolutions and crystallization mechanisms of liquid metal Ni during solidification process, MD simulation studies have been performed under 7 pressures of 0 ˜ 30 GPa, at cooling rate of 1.0 × 1011 K s-1. Adopting several microstructural analyzing methods, especially the cluster-type index method (CTIM-2) to analyze the local microstructures in the system. It is found that the pressure has important influence on the formation and evolution of microstructures, especially of the main basic clusters in the system. All the simulation systems are directly solidified into crystal structures, and the 1421, 1422, 1441 and 1661 bond-types, as well the FCC (12 0 0 0 12 0), HCP (12 0 0 0 6 6) and BCC (14 6 0 8 0 0) clusters play a key role in the microstructure transitions from liquid to crystal structures. The crystallization temperature T c is enhanced almost linearly with the increase of pressure. Highly interesting, it is found for the first time that there is an important phase transformation point from FCC to BCC structures between 20 ˜ 22.5 GPa during the solidification processes from the same initial liquid system at the same cooling rate. And the effect of increasing pressure is similar to that of decreasing cooling rate for the phase transformation of microstructures during solidification process of liquid metal Ni system, though they have different concrete effecting mechanisms.

Project Description and Publications List for UAH CMMR

NASA Technical Reports Server (NTRS)

Kaukler, William F.

1999-01-01

This research combines a state of the art X-ray Transmission Microscope, XTM, with a specially designed x-ray transparent horizontal Bridgman furnace to image (with resolutions up to 3 micrometers) the solidification of metal alloys in real-time. The objective is to obtain real-time dynamic data to provide direct measure of the solute profile in the liquid, phase coalescence and growth in the liquid, and the detailed interface morphology (e,g., dendrites and cells) during solidification. We are also enhancing the XTM data with precise solid-liquid interfacial temperature and the thermal gradient measurement techniques, and working on the application of this technology to the study of the fundamentals of solidification in microgravity. Over the last several years we have successfully imaged in real-time: interfacial-morphologies, phase growth, coalescence, incorporation of phases into the growing interface, and the solute boundary layer in the liquid at the solid-liquid interface. We have also measured true local growth rates and can evaluate segregation structures in the solid. Interfacial undercoolings are being measured either with a special Seebeck furnace or with micro-thermocouple arrays we are developing. These later techniques are presently being incorporated with the XTM furnace. This last year emphasized the investigation of the solute layer in the melt during solidification. Methods were developed to quantify the solute concentrations using x-ray absorption and to compare to predictions from simulations. In addition, work is being completed on a brass-board portable XTM that incorporates a vertical Bridgman furnace.

Contribution to "AIAA Aerospace Year in Review" article

NASA Technical Reports Server (NTRS)

Grugel, Richard N.; Downey, J. Patton

2012-01-01

The NASA Marshall Space Flight Center Microgravity Science Program is dedicated to promoting our understanding of materials processing by conducting relevant experiments in the microgravity environment and supporting related modeling efforts with the intent of improving ground-based practices. Currently funded investigations include research on dopant distribution and defect formation in semiconductors, microstructural development and transitions in dendritic casting alloys, coarsening phenomena, competition between thermal and kinetic phase formation, and the formation of glassy vs. crystalline material. NASA Microgravity Materials Science Principle Investigators are selected for funding either through a proposal in response to a NASA Research Announcement or by collaborating on a team that has successfully proposed to a foreign space agency research announcement. In the latter case, a US investigator can then apply to NASA for funding through an unsolicited proposal. The International Space Station (ISS) facilities used for the experimental investigations are provided primarily by partnering with foreign agencies and often US investigators are working as a part of a larger team studying a specific area of materials science. Facilities for conducting experiments aboard the ISS include the European Space Agency (ESA) Low Gradient Facility (LGF) and the Solidification and Quench (SQF) modular inserts to the Materials Research Rack/Materials Science Laboratory and are primarily used for controlled solidification studies. The French Space Agency (CNES) provided DECLIC facility allows direct observation of morphological development in transparent materials that solidify analogously to metals. The ESA provided Electro ]Magnetic Levitator (EML) is designed to levitate, melt and then cool samples in order to determine material properties, study nucleation behavior, and document phase transitions. Finally, the Microgravity Science Glovebox (MSG) serves as a onboard facility for supporting the hardware required to conduct a number of smaller, short-term investigations.

International Space Station (ISS)

NASA Image and Video Library

2002-07-05

Expedition Five flight engineer Peggy Whitson is shown installing the Solidification Using a Baffle in Sealed Ampoules (SUBSA) experiment in the Microgravity Science Glovebox (MSG) in the Destiny laboratory aboard the International Space Station (ISS). SUBSA examines the solidification of semiconductor crystals from a melted material. Semiconductor crystals are used for many products that touch our everyday lives. They are found in computer chips, integrated circuits, and a multitude of other electronic devices, such as sensors for medical imaging equipment and detectors of nuclear radiation. Materials scientists want to make better semiconductor crystals to be able to further reduce the size of high-tech devices. In the microgravity environment, convection and sedimentation are reduced, so fluids do not remove and deform. Thus, space laboratories provide an ideal environment of studying solidification from the melt. This investigation is expected to determine the mechanism causing fluid motion during production of semiconductors in space. It will provide insight into the role of the melt motion in production of semiconductor crystals, advancing our knowledge of the crystal growth process. This could lead to a reduction of defects in semiconductor crystals produced in space and on Earth.

Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhao, Cang; Fezzaa, Kamel; Cunningham, Ross W.

Here, we employ the high-speed synchrotron hard X-ray imaging and diffraction techniques to monitor the laser powder bed fusion (LPBF) process of Ti-6Al-4V in situ and in real time. We demonstrate that many scientifically and technologically significant phenomena in LPBF, including melt pool dynamics, powder ejection, rapid solidification, and phase transformation, can be probed with unprecedented spatial and temporal resolutions. In particular, the keyhole pore formation is experimentally revealed with high spatial and temporal resolutions. The solidification rate is quantitatively measured, and the slowly decrease in solidification rate during the relatively steady state could be a manifestation of the recalescencemore » phenomenon. The high-speed diffraction enables a reasonable estimation of the cooling rate and phase transformation rate, and the diffusionless transformation from β to α’ phase is evident. The data present here will facilitate the understanding of dynamics and kinetics in metal LPBF process, and the experiment platform established will undoubtedly become a new paradigm for future research and development of metal additive manufacturing.« less