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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1988

Rapid solidification of Nb-base alloys

New Nb-base alloys are of interest for aerospace structural applications at high temperatures, viz, 800 to 1650 C. Fundamental information regarding the effects of rapid solidification in achieving greatly refined microstructures, extended solid solubility, suppression of embrittling equilibrium phases, and formation of new phases is desired in a number of Nb-X alloys. The microstructures and selected properties of Nb-Si and other Nb-base alloys are presented for materials both rapidly quenched from the equilibrium liquidus and rapidly solidified following deep supercooling. Electromagnetic levitation was used to achieve melting and supercooling in a containerless inert gas environment. A variety of solidification conditions were employed including splatting or drop casting of supercooled samples. The morphology and composition of phases formed are discussed in terms of both solidification history and bulk composition.

Gokhale, A. B.↗
DOE OSTI2021

Tusas: A fully implicit parallel approach for coupled phase-field equations

In this study, we develop a fully-coupled, fully-implicit approach for phase-field modeling of solidification in metals and alloys. Predictive simulation of solidification in pure metals and metal alloys remains a significant challenge in the field of materials science, as microstructure formation during the solidification process plays a critical role in the properties and performance of the solid material. Our simulation approach consists of a finite element spatial discretization of the fully-coupled nonlinear system of partial differential equations at the microscale, which is treated implicitly in time with a preconditioned Jacobian-free Newton-Krylov method. The approach is algorithmically scalable as well as efficient due to an effective preconditioning strategy based on algebraic multigrid and block factorization. We implement this approach in the open-source Tusas framework, which is a general, flexible tool developed in C++ for solving coupled systems of nonlinear partial differential equations. The performance of our approach is analyzed in terms of algorithmic scalability and efficiency, while the computational performance of Tusas is presented in terms of parallel scalability and efficiency on emerging heterogeneous architectures. We demonstrate that modern algorithms, discretizations, and computational science, and heterogeneous hardware provide a robust route for predictive phase-field simulation of microstructure evolution during additive manufacturing.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1991

The role of gravity on macrosegregation in alloys

During dendritic solidification liquid flow is induced both by buoyancy forces and solidification shrinkage. There is strong evidence that the major reason for the liquid flow is the former, i.e., thermosolutal convection. In the microgravity environment, it is thought that the thermosolutal convection will be greatly diminished so that convection will be confined mainly to the flow of interdendritic liquid required to satisfy the solidification shrinkage. An attempt is made to provide improved models of dendritic solidification with emphasis on convection and macrosegregation. Macrosegregation is an extremely important subject to the commercial casting community. The simulation of thermosolutal convection in directionally solidified (DS) alloys is described. A linear stability analysis was used to predict marginal stability curves for a system that comprises a mushy zone underlying an all-liquid zone. The supercritical thermosolutal convection in directionally solidified dendritic alloys was also modeled. The model assumes a nonconvective initial state with planar and horizontal isotherms and isoconcentration that move upward at a constant solidification velocity. Results are presented for systems involving lead-tin alloys and show significant differences with results of plane-front solidification.

Poirier, D. R.↗
NASA NTRS1986

Activities of the Center for the Space Processing of Engineering Materials

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.

Source record↗
DOE OSTI2020

Microstructural characterization of dendritic evolution using two-point statistics

Characterizing large four-dimensional materials datasets is difficult due to the presence of complex mi- crostructures and time-varying length scales. We showcase the use of two-point statistics as an efficient and un-biased way of extracting materials parameters from an Al-Cu alloy during solidification. The evo- lution of dendrite primary arm thickness, average secondary arm spacing, and average tip-to-tip spacing were tracked using two-point Pearson auto-correlations of scaled mean curvatures. Insights into compet- itive side-branching are also reported. We show both visually and quantitatively that most length scales change rapidly during early stages of dendritic growth, but slow as diffusion fields of dendrites overlap.

Aluminum alloys↗
NASA NTRS1982

Solidification studies of Nb-Ge alloys at large degrees of supercooling

A 32 meter evacuated drop tube has been used to investigate the solidification of Nb-Ge alloys after deep undercooling. Samples have been supercooled as much as 500 K below the liquidus by using free-fall conditions to eliminate crucible induced nucleation. Final microstructures are dependent on the quenching rates at the bottom of the drop tube with a striking extension of the beta phase solubility limit at the higher quenching rates.

Lacy, L. L.↗
DOE OSTI2020

Thermomagnetic Processing of Aluminum Alloys During Heat Treatment

Processing materials under magnetic fields is an underexplored technique to improve structure and mechanical properties in metals and alloys. Magnetic fields can alter phase stability, modify diffusion characteristics, and alter material flow substantially. In castings, magnetic fields can be used during melting of the alloy, during solidification, or during postprocessing operations such as heat treatment to achieve structural changes. This work investigates the effectiveness of thermomagnetic processing during heat treatment of Al alloys containing in the Al–Cu, Al–Si–Cu, and Al–Mg–Ce systems. We demonstrate an improvement in mechanical properties and a reduction in required heat treatment times for all alloys.

36 MATERIALS SCIENCE↗
NASA NTRS1987

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

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.

Decarlo, J. L.↗
NASA NTRS1980

Preparation of monotectic alloys having a controlled microstructure by directional solidification under dopant-induced interface breakdown

Monotectic alloys having aligned spherical particles of rods of the minor component dispersed in a matrix of the major component are prepared by forming a melt containing predetermined amounts of the major and minor components of a chosen monotectic system, providing in the melt a dopant capable of breaking down the liquid solid interface for the chosen alloy, and directionally solidfying the melt at a selected temperature gradient and a selected rate of movement of the liquid-solid interface (growth rate). Shaping of the minor component into spheres or rods and the spacing between them are controlled by the amount of dopant and the temperature gradient and growth rate values. Specific alloy systems include Al Bi, Al Pb and Zn Bi, using a transition element such as iron.

Parr, R. A.↗
NASA NTRS1994

Interactions between solidification and compositional convection in mushy layers

Mushy layers are ubiquitous during the solidification of alloys. They are regions of mixed phase wherein solid crystals are bathed in the melt from which they grew. The matrix of crystals forms a porous medium through which the melt can flow, driven either by external forces or by its own buoyancy in a gravitational field. Buoyancy-driven convection of the melt depends both on temperature gradients, which are necessary for solidification, and on compositional gradients, which are generated as certain components of the alloy are preferentially incorporated in the solid phase and the remaining components are expelled into the melt. In fully liquid regions, the combined action of temperature and concentration on the density of the liquid can cause various forms of double-diffusive convection. However, in the interior of mushy regions the temperature and concentration are thermodynamically coupled so only single-diffusive convection can occur. Typically, the effect of composition on the buoyancy of the melt is much greater than the effect of temperature, and thus convection in mushy layers in driven primarily by the computational gradients within them. The rising interstitial liquid is relatively dilute, having come from colder regions of the mushy layer, where the liquidus concentration is lower, and can dissolve the crystal matrix through which it flows. This is the fundamental process by which chimneys are formed. It is a nonlinear process that requires the convective velocities to be sufficiently large, so fully fledged chimneys (narrow channels) might be avoided by means that weaken the flow. Better still would be to prevent convection altogether, since even weak convection will cause lateral, compositional inhomogeneities in castings. This report outlines three studies that examine the onset of convection within mushy layers.

Worster, M. Grae↗
NASA NTRS1993

The influence of a microgravity environment on the dendritic morphology during directional solidification of hypoeutectic Al-Si alloys

NASA grant NAGW-2540 provided the opportunity to evaluate and extend ongoing studies of directionally solidified Al-Si alloys. Microstructural development was further characterized in terms of solidification processing parameters; novel relationships between processing and development of dendrite trunk diameters and tertiary dendrite arm spacings were found. This has resulted in three publications (one in print, one in press, and one in review). Microstructural development under conditions of controlled acceleration during directional solidification has been investigated; this has culminated in a Master's degree and will be submitted for publication. The above work not only contributes to our understanding of solidification phenomena but also defines the processing parameters for a successful microgravity experiment while providing a data base to which mu g samples can be unequivocally compared and evaluated.

Grugel, Richard N.↗
NASA NTRS1985

MPS solidification model. Analysis and calculation of macrosegregation in a casting ingot

Work performed on several existing solidification models for which computer codes and documentation were developed is presented. The models describe the solidification of alloys in which there is a time varying zone of coexisting solid and liquid phases; i.e., the S/L zone. The primary purpose of the models is to calculate macrosegregation in a casting or ingot which results from flow of interdendritic liquid in this S/L zone during solidification. The flow, driven by solidification contractions and by gravity acting on density gradients in the interdendritic liquid, is modeled as flow through a porous medium. In Model 1, the steady state model, the heat flow characteristics are those of steady state solidification; i.e., the S/L zone is of constant width and it moves at a constant velocity relative to the mold. In Model 2, the unsteady state model, the width and rate of movement of the S/L zone are allowed to vary with time as it moves through the ingot. Each of these models exists in two versions. Models 1 and 2 are applicable to binary alloys; models 1M and 2M are applicable to multicomponent alloys.

Poirier, D. R.↗
NASA NTRS1991

Phase selection during crystallization of undercooled liquid eutectic lead-tin alloys

During rapid solidification substantial amounts of undercooling are in general required for formation of metastable phases. Crystallization at varying levels of undercooling and melting of metastable phases were studied during slow cooling and heating of emulsified PB-Sn alloys. Besides the experimental demonstration of the reversibility of metastable phase equilibra, two different principal solidification paths have been identified and compared with the established metastable phase diagram and predictions from classical nucleation theory. The results suggest that the most probable solidification path is described by the 'step rule' resulting in the formation of metastable phases at low undercooling, whereas the stable eutectic phase mixture crystallizes without metastable phase formation at high undercooling.

Fecht, H. J.↗
NASA NTRS1984

Microsegregation during directional solidification

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.

Coriell, S. R.↗
NASA NTRS1972

Eutectic superalloys strengthened by delta Ni3Cb lamellae, and gamma prime, Ni3Al precipitates.

Bivariant eutectic alloys, located on a liquidus surface within the Ni-Cb-Cr-Al quaternary, were identified which permitted the production of aligned delta Ni3Cb lamellae within a nichrome matrix containing the fcc precipitate gamma prime Ni3Al. The volume fraction of delta and gamma prime could be varied significantly by compositional changes. After directional solidification certain alloys possessed improved ductility and corrosion resistance with respect to the Ni3Al-Ni3Cb eutectic, while their values of tensile and creep strength approached or exceeded those for the Ni3Al-Ni3Cb pseudobinary system. The mechanical properties of the directionally solidified alloy, Ni-19.7 wt % Cb-6.0 wt % Cr-2.5 wt % Al, were evaluated. Its longitudinal strength in tension and creep was found to be superior to all advanced nickel base superalloys. It is thus demonstrated that useful properties for gas turbine airfoil applications can be achieved by reinforcing a strong and tough gamma nichrome matrix containing precipitated gamma prime by a strong lamellar intermetallic compound having greater strength at elevated temperature.

Lemkey, F. D.↗
NASA NTRS1986

Behavior of insoluble particles during parabolic flight solidification processing of Fe-C-Si and Fe-C-V alloys

In a high-g rapid solidification environment, Fe-base alloy insoluble particles at the solidification interface may be pushed ahead of the interface or may be trapped in the solid, depending on the correlation of various interface energies, the solidification rates, and the Stokes force; particle agglomeration due to buoyancy-driven convection further complicates the problem. Attention is presently given to results obtained for directionally solidified Fe-C-Si and Fe-C-V alloys during parabolic low-g flight and ground experiments. In these systems, graphite and vanadium carbide can be considered to be the insoluble particles.

Stefanescu, D. M.↗
NASA NTRS1988

Directional solidification of lead-copper immiscible alloys in a cyclic gravity environment

Hypermonotectic copper-lead alloys were directionally solidified at unit gravity on earth and also in the cyclic gravitational environment attainable during flight of NASA's KC-135 aircraft. In both cases macrosegregation developed that consisted of an initial lead-rich phase above which an aligned composite structure of apparent monotectic composition grew. Differences within these regions are examined, and the suitability of the KC-135 environment for directional solidification of monotectic alloys is discussed.

Shah, S.↗