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At least 397 records · Page 22

Apatite-Melt Partitioning of Volatiles in Basaltic Systems: Implications for Determining Volatile Abundances in Planetary Bodies from Apatite

Apatite [Ca5(PO4)3(F,Cl,OH)] is present in a wide range of planetary materials, and due to the presence of volatiles within its crystal structure (X-site), many recent studies have attempted to use apatite to constrain the volatile contents of planetary magmas and mantle sources [i.e., 1]. Experimental studies have investigated the apatite-melt partitioning behavior of F, Cl, and OH in basaltic systems [e.g., 2- 3], reporting that apatite-melt partitioning of volatiles is best described as exchange equilibria similar to Fe-Mg partitioning between olivine and silicate melt. However, exchange coefficients may vary as a function of temperature, pressure, melt composition, and/or oxygen fugacity. Furthermore, exchange coefficients may vary in portions of apatite compositional space where F, Cl, and OH do not mix ideally in apatite [3]. In these regions of ternary space, we anticipate that crystal chemistry could influence partitioning behavior. Consequently, we conducted experiments to investigate the effect of apatite crystal chemistry on apatite-melt partitioning of F, Cl, and OH.

McCubbin, F. M.↗

Seasonal Monitoring of Melt and Accumulation Within the Deep Percolation Zone of the Greenland Ice Sheet and Comparison with Simulations of Regional Climate Modeling

Increasing melt over the Greenland Ice Sheet (GrIS) recorded over the past several years has resulted in significant changes of the percolation regime of the ice sheet. It remains unclear whether Greenland's percolation zone will act as a meltwater buffer in the near future through gradually filling all pore space or if near-surface refreezing causes the formation of impermeable layers, which provoke lateral runoff. Homogeneous ice layers within perennial firn, as well as near-surface ice layers of several meter thickness have been observed in firn cores. Because firn coring is a destructive method, deriving stratigraphic changes in firn and allocation of summer melt events is challenging. To overcome this deficit and provide continuous data for model evaluations on snow and firn density, temporal changes in liquid water content and depths of water infiltration, we installed an upward-looking radar system (upGPR) 3.4 m below the snow surface in May 2016 close to Camp Raven (66.4779 deg N, 46.2856 deg W) at 2120 m a.s.l. The radar is capable of quasi-continuously monitoring changes in snow and firn stratigraphy, which occur above the antennas. For summer 2016, we observed four major melt events, which routed liquid water into various depths beneath the surface. The last event in mid-August resulted in the deepest percolation down to about 2.3 m beneath the surface. Comparisons with simulations from the regional climate model MAR are in very good agreement in terms of seasonal changes in accumulation and timing of onset of melt. However, neither bulk density of near-surface layers nor the amounts of liquid water and percolation depths predicted by MAR correspond with upGPR data. Radar data and records of a nearby thermistor string, in contrast, matched very well for both timing and depth of temperature changes and observed water percolations. All four melt events transferred a cumulative mass of 56 kg/(sq. m) into firn beneath the summer surface of 2015. We find that continuous observations of liquid water content, percolation depths and rates for the seasonal mass fluxes are sufficiently accurate to provide valuable information for validation of model approaches and help to develop a better understanding of liquid water retention and percolation in perennial firn.

Heilig, Achim↗

Hyper-cooling Limit, Heat of Fusion, and Temperature-Dependent Specific Heat of Fe-Cr-Ni Melts

Thermophysical properties of Fe-Cr-Ni melts are studied using electrostatic levitation and rapid solidification techniques. Six hypoeutectic Fe(sub 0.72)Cr(sub w)Ni(sub(0.28−w)) alloys with a Cr/Ni ratio of around 0.8 were melted and solidified at different degrees of undercooling. From the observed relationship between the undercooling and thermal plateau time, the hyper-cooling limit and heat of fusion of Fe(sub 0.72)Cr(sub w)Ni(sub(0.28−w)) melts are determined as a function of Cr mass fraction. A ratio of specific heat and total hemispherical emissivity of the Fe-Cr-Ni melts is calculated using the time-temperature profiles. A new method is presented to evaluate the temperature dependence of specific heat for undercooled melts and applied to this alloy family.

Sangho Jeon↗

The 32-year Record-high Surface Melt in 2019/2020 on the Northern George VI Ice Shelf, Antarctic Peninsula

In the 2019/2020 austral summer, the surface melt duration and extent on the northern George VI Ice Shelf (GVIIS) was exceptional compared to the 31 previous summers of distinctly lower melt. This finding is based on analysis of near-continuous 41-year satellite microwave radiometer and scatterometer data, which are sensitive to meltwater on the ice shelf surface and in the near-surface snow. Using optical satellite imagery from Landsat 8 (2013 to 2020) and Sentinel-2 (2017 to 2020), record volumes of surface meltwater ponding were also observed on the northern GVIIS in 2019/2020, with 23 % of the surface area covered by 0.62 km3 of ponded meltwater on 19 January. These exceptional melt and surface ponding conditions in 2019/2020 were driven by sustained air temperatures ≥0 ∘C for anomalously long periods (55 to 90 h) from late November onwards, which limited meltwater refreezing. The sustained warm periods were likely driven by warm, low-speed (≤7.5 m s−1) northwesterly and northeasterly winds and not by foehn wind conditions, which were only present for 9 h total in the 2019/2020 melt season. Increased surface ponding on ice shelves may threaten their stability through increased potential for hydrofracture initiation; a risk that may increase due to firn air content depletion in response to near-surface melting.

Alison F. Banwell↗

Pink Spinel in Apollo Impact Melt Rock 68815: Implications for Mg-Suite Magmatism

Introduction: Magnesian rocks from the lunar highlands are collectively termed the Mg-suite. Characterized by high (>60) Mg# (molar 100×Mg/[Mg+Fe]) in mafic phases and calcic plagioclase, these rocks are plutonic to hypabyssal in origin, and include a range of bulk mineralogies such as troctolites, dunites, norites, gabbronorites, and spinel troctolites [1]. These Mg-suite lithologies have distinct trace element concentrations and ratios that differentiate them from other lunar rock types. These rocks are ancient, generally dated to between 4.5 and 4.1 Ga, although it is unknown if this represents the full range of Mg-suite ages [1–2]. Among the Mg-suite lithologies, the spinel troctolites are relatively rare, to date only found in polymict breccias [3]. Spinel troctolites, as their name suggests, consist of calcic plagioclase and forsteritic olivine, with minor amounts of spinel (MgAl2O4), ± pyroxene and cordierite [1,4]. This form of spinel is often called ‘pink’ spinel because of its appearance in thin section under plane polarized light (PPL; Fig. 1), due to minor amounts of Cr. Spinel troctolites are generally plutonic or hypabyssal in origin (subsequently exhumed and incorporated into polymict breccias), or formed through impact processes (e.g., crystalline impact melt) [5]. A spinel-rich lithology has also been found in the Moscoviense region of the Moon via the Moon Mineralogy Mapper (M3) and lacks other mafic phases [6]. Finally, while the Mg-suite sampled thus far consists of plutonic (or hypabyssal) rocks, the question remains if such magmas could have erupted on the surface of the Moon [7]. These magmas have much lower density than mare basalts, but little sample or remote sensing evidence has been found to support the idea that extrusive Mg-suite volcanism occurred [7]. Here, we present a coordinated microanalytical study of spinel-bearing lithic and mineral clasts found in Apollo sample 68815. These data will be used to understand their petrogenesis (magmatic or impact) and modification histories, and to shed light on the existence of volcanic Mg-suite rocks. Sample Description: Apollo sample 68815 is a polymict impact melt breccia containing a variety of lithic and mineral fragments embedded in devitrified impact melt. This sample was chipped off the top of a boulder at Station 8 during the Apollo 16 mission and had an original weight of nearly 1.8 kg. In this study, we investigated two polished thin sections of 68815: 68815,17 and 68815,148, both containing spinel. Methods: The thin sections of 68815 were studied using optical light microscopy (PPL, cross-polarized light, and reflected light) with a Keyence VHX-7100 Digital Microscope. Each section was then X-ray mapped for 13–14 elements using a Cameca SX100 electron probe microanalyzer (EPMA) located in the Kuiper Materials Imaging and Characterization Facility (KMICF) at the University of Arizona. We have obtained geochemical information about the phases (olivine, plagioclase, spinel, pyroxene) in the thin sections also using the EPMA. In addition, we have used ThermoScientific Helios NanoLab 660 Focused-Ion-Beam Scanning-Electron Microscope (FIB-SEM) and a Hitachi S-4800 SEM (both in KMICF) to obtain backscattered electron (BSE) images and energy dispersive Xray spectrometry (EDS) maps of areas of interest. Using a JEOL 7900F SEM at the Astromaterials Research & Exploration Science (ARES) at NASA Johnson Space Center (JSC), we have obtained electron backscatter diffraction (EBSD) maps of the spinel-bearing portions of the thin sections. The EBSD data were collected under beam conditions of 20 kV, and ~90 μA, with step sizes varying from 0.05 to 2 μm. Following EBSD data collection, we processed the data using AZtecCrystal and MTEX, a free MATLAB toolbox. Results: We have found clasts with subophitic textures, that consist of primarily olivine and plagioclase, with minor amounts of pink Mg-Al spinel and pyroxene (Fig. 1). These clasts are up to ~1 mm in length and contain spinels up to 50 μm across. We have additionally identified pink Mg-Al spinels within the impact melt (i.e., not contained in lithic clasts) in both thin sections. In one instance, a single spinel grain is approximately 300 μm across (Fig. 1b, 2). The spinel fragments embedded in impact melt have varying compositions, typically distinct from the compositions of spinels in the lithic clasts. Spinel-Bearing Clasts: Ten lithic clasts with similar textures and mineral compositions were identified between 68815,17 (two clasts) and ,148 (eight clasts). These clasts fall into two groups. The first has skeletal olivine with intergranular plagioclase, with minor amounts of pyroxene and spinel (Fig. 1a, 2c, 2d). The spinel in these clasts are found amid the plagioclase. The second group have an intergranular texture of olivine and plagioclase, again with minor spinel and pyroxene. The second group may contain spinels surrounded by plagioclase, and spinels enclosed in olivine. Spinels located within both clast types range from no apparent Cr zoning, to reverse zoning (Cr-enrichment inward; Fig. 2d), to normal zoning (Cr-enrichment outward). In the clasts thus far investigated with EPMA, plagioclase compositions range from An# (molar 100×Ca/[Ca+Na+K]) 92–96. Olivine Mg# ranged from 77 to 94, while pyroxene had Mg# from 54–84. Spinel in the clasts have Cr# (molar 100×Cr/[Cr+Al]) 2–4 and Mg# 88–91, which is within the range of pristine and plutonic spinel troctolites [8]. Isolated Spinels: These crystals are generally euhedral to subhedral, and can exhibit reverse Cr zoning (Cr enrichment inward) or no apparent Cr zoning. The spinels thus far investigated via EPMA have Cr# 9–14 and Mg# 65–82. The Cr# for these spinels is within the range reported by [8], but have lower Mg#. Future Work: We will continue to process the EBSD data for these lithic and mineral clasts. We will also continue to characterize these clasts using EPMA and SEM. By thoroughly characterizing the various spinels and spinel-bearing clasts, we aim to constrain the petrogenesis of these minerals and rock fragments. Acknowledgments: We thank NASA for the loan of these thin sections. We thank Ken Domanik and Jerry Chang for their support with data collection. Work was supported by a University of Arizona RII Core Facilities Pilot Program grant and start-up funds to JJB. We acknowledge support from NASA’s Planetary Science Research program for analysis performed at JSC. References: [1] Shearer C. K. et al. (2015) Am. Min. 100, 294–325. [2] Borg L. E. et al. (2020) GCA 290, 312–332. [3] Warren P. H. (1993) Am. Min. 78, 360–376. [4] Dymek R. F. et al. (1976) LPS VII, 2335–2378. [5] Treiman et al. (2019) Am. Min. 104, 370–384. [6] Pieters et al. (2011) JGR: Plan. 116:E00G08. [7] Prissel et al. (2016) Icarus 277, 319–329. [8] Prissel et al. (2016) Am. Min. 101, 1624–1635.

spinel↗

Temperature Effect on Silicate Melt-Sulfide-Metal Trace Element Partitioning in the Presence of Sulfur Under Reduced Conditions

The reduced nature of Mercury, enstatite chondrites, and the aubrite parent bodies (APB) have raised many questions regarding the geochemical behavior of typically lithophile, heat-producing, and rare-earth elements (REE) in magmas at low oxygen fugacity (fO2). Due to decreasing O availability at these low fO2, and an abundance of S(sup 2(-)), sulfur (S) acts as an important anion that changes the partitioning behavior of many elements and modifies the physical properties of silicate melts. Preliminary observations suggest that major and minor elements exhibit different geochemical affinities in highly reduced, S-rich systems compared to terrestrial rocks. The speciation and bonding environment of S, dictated by P/T/fO2 conditions, may strongly influence the degree to which S affects partitioning behavior. Here we investigate the partitioning behavior of major, minor, and trace elements between silicate melt, sulfide melt, and metal as well as the coordination chemistry of S in highly reduced silicate melts. Our work is focused on investigating solely the entropy-dependent temperature effect on partitioning of elements for which we currently have MESSENGER data (K, Na, Th, U, Si, Mg, Fe, Ti, Ca, Al, Cr, Mn, S, Cl) as well as a host of geochemically relevant trace elements such as REEs (P, Co, Ni, Mo, Ce, Nd, Sm, Eu, Gd, Dy, Yb). Previous studies in which temperature, pressure, and fO2 were co-varied found that as fO2 decreases, heat-producing elements U and Th become more chalcophile, while K becomes less chalcophile. Concurrently, nominally lithophile elements Mg and Ca become more chalcophile and were observed as minor elements in exsolved sulfides and bonded with S species in silicate melt. These studies, however, could not disentangle entropic effects from changes in the fO2. New temperature-dependent partitioning data from our work will be used to determine which elements are most likely to retain their lithophile character and hence be incorporated into silicates, and which elements are likely contained within the sulfide (chalcophile) and metal core (siderophile), setting the stage for the thermal and magmatic evolution of reduced planetary bodies.

B A Anzures↗

Ice Sheet Melt Water Profile Mapping Using Multi-frequency Microwave Radiometry

For understanding englacial hydrology and its impact on ice sheet mass balance, observations of the liquid water content (LWC) within the ice sheets are needed. Earlier studies have shown the complementary nature of multi-frequency microwave radiometer measurements to detect subsurface LWC distribution in addition to surface LWC, which is critical for understanding the seasonal melt dynamics of ice sheets. In this study, we used 1.4 GHz brightness temperature (TB) measurements from the NASA Soil Moisture Active Passive (SMAP) satellite, and 6.9, 10.7, 18.9, and 36.5 GHz TB measurements from the JAXA Global Change Observation Mission-Water Shizuku (GCOM-W) satellite to investigate the multi-frequency response at pan-Greenland scale. The melt indications derived at different frequencies show trends consistent with persistent seasonal subsurface melt water and delayed subsurface refreezing of the seasonal melt water. The result suggests that the seasonal subsurface persistent melt water occurrences that are not captured by the high-frequency retrievals are both temporally and spatially very significant.

Burgin, Mariko↗

Detached Melt and Vapor Growth of InI in SUBSA hardware

Indium iodide (InI) single crystals, grown by the Bridgman process, have shown a significant promise as room temperature detector material for X-rays and γ-rays due to the large, close to ideal, bandgap of Eg = 2 eV, and high electrical resistivity. Yet the transport properties of the charge and the detector performance remain inadequate. The Bridgman growth of semiconductor crystals in microgravity have typically resulted in partial dewetting and Marangoni convection, which disturbed the diffusion-controlled growth and produced nonuniform dopant distribution. However, unconfined or partially confined solidification drastically reduced the number of stress-induced defects compared to the confined growth in crucibles on Earth.The goal of the present investigation was to explore melt growth of a heavy metal halide in microgravity, focusing on dewetting, in order to improve the crystalline perfection, i.e., to reduce the number of stress-related defects. InI was chosen because it is non-toxic and has a low melting point of only 365 C (~150 C below the melting point of InSb, used in the SUBSA experiments in 2002). Furthermore, InI melts and evaporates congruently, making it suitable for both growth by directional solidification and growth from the vapor phase. In preparation for the flight experiments, ground-based experiments were conducted in the SUBSA ground unit, consisting of 4 melt growth and 2 vapor growth experiments. The crystals were grown by a gradient freeze method by lowering the setpoint of the furnace. The transparent section of the SUBSA furnace did not allow observations of the solid-liquid interface. Contrary to our expectations, the possible occurrence of dewetting during growth could not be observed. We will present i) the ampoule design and preparation, ii) the experiments conducted in the SUBSA ground unit, iii) the images obtained during the microgravity experiments and iv) the results of the characterization of the grown crystals and detector fabrication.

Crystal Growth↗

A Daily Surface Melt Product From Passive Microwave Swath Observations for Arctic Sea Ice Studies

Most passive microwave sea ice data products are produced with daily gridded brightness temperatures. However, a single polar-orbiting passive microwave instrument makes many measurements per day where swaths overlap in the polar regions. These level 1 swath brightness temperature observations can be used to derive information on sub-daily sea ice processes. One such process is the rapid transition of snow and ice between freezing and melting due to diurnal freeze-thaw cycling or brief warming events in the pre-melt season. Here, a new method utilizing the sub-daily variability in swath-to-swath observations is used to produce daily, binary maps of the melting status on Arctic Sea ice using Level 1C brightness temperatures from the Special Sensor Microwave Imager and Sounder (SSM/I-SSMIS) data record. The resulting data set will enable investigations of the frequency, inter-annual variability, and spatial extent of brief surface melting events occurring in the winter and shoulder seasons outside of the traditional summer melt season.

Angela C. Bliss↗

Beyond Melting: Amorphous Bonding for Joining and Consolidation

Crystallization may be the hidden constraint in thermoplastic composite manufacturing. It requires tightly controlled cooling, induces residual stresses through shrinkage, and introduces path-dependent behavior that complicates predictive modeling yet remains essential for structural performance. This work asks: can bonding be achieved without relying on melt-driven crystallization? To address this, thin (5–20 μm) polyetherimide (PEI) interlayers are pre-healed to slow-cooled polyaryletherketone (PAEK) in two contexts. The first, Thermabond®, is sub-melt joining of low melt-PAEK laminates. Results show that bond quality is governed primarily by processing (i.e., adequate healing and film handling) rather than modest changes in interlayer thickness. This concept is then extended to laminate-scale manufacturing through an architecture known as OATMEAL (Out-of-autoclave Amorphous/semicrystalline Thermoplastic Material for Energy-efficient Aerospace-grade Laminates). PEI is healed to carbon fiber reinforced polyetheretherketone (PEEK) at the prepreg and excess PEI is then ablated from the surface. Crystallinity is developed off-line during prepreg fabrication, while subsequent consolidation occurs below the melt temperature to preserve it. Cross-ply warpage experiments show that, contrary to intuition, repeated amorphous interfaces reduce global curvature by lowering the effective stress lock-in temperature and eliminating crystallization shrinkage from the lamina response. Correspondingly, laminate behavior is accurately predicted using classical laminate theory (CLT) with a single effective stress-free temperature, whereas conventional CF/PEEK requires accounting for crystallization-driven effects. By decoupling interfacial healing from crystallization, OATMEAL enables sub-melt consolidation, reduces energy consumption by up to 75%, and increases manufacturing throughput by fivefold. These results demonstrate that amorphous bonding is not only a joining strategy, but a pathway to more predictable and scalable thermoplastic composite manufacturing.

solidification↗

Multi phenomena melt pool sensor data fusion for enhanced process monitoring of laser powder bed fusion additive manufacturing

Finding actionable trends in laser-based metal additive manufacturing process monitoring data is challenging owing to the diversity and complexity of the underlying physical interactions. A single monitoring solution that captures a particular process phenomenon, such as a photodiode that tracks melt pool intensity, is not alone capable of evaluating process stability or detecting flaw formation with sufficient precision for routine application in industry. In this work, to improve flaw detection performance, we adopted a data fusion approach that captures multiple process phenomena. To demonstrate this, we acquired data from laser powder bed fusion (LPBF) builds of cylindrical specimens produced with different laser spot sizes, emulating defocusing due to process faults such as thermal lensing. The resulting specimens had porosity of varying types and severity, quantified by post-build non-destructive X-ray computed tomography, Archimedes density measurements, and destructive metallographic characterization. During the build, the melt pool state was monitored with two coaxial high-speed video cameras and a temperature field imaging system. Physically intuitive low-level melt pool signatures, such as melt pool temperature, shape and size, and spatter intensity were extracted from this high-dimensional, image-based sensor data. These process signatures were subsequently used as input features in relatively simple machine learning models, such as a support vector machine, which were trained to detect laser defocusing, and in addition, predict porosity type and severity. The results show that the data fusion approach significantly enhanced system performance by reducing the overall false positive rate from ~ 0.1 to ~ 0.001 without sacrificing the true positive rate (~0.90). These results were at par with a black-box, deep machine learning approach (convolutional neural network).

36 MATERIALS SCIENCE↗

Laser‐Powder Melt Pool Solidification Dynamics and Microstructural Engineering of Ti‐5553 Microlattices

The fine geometric and topological control afforded by additive manufacturing technologies has enabled the manufacture of architected materials across length scales, and enabling tunable mechanical performance as a function of local and global design. Progress has been made to tune the mechanical response of architected materials through geometry, but understanding how the geometry and processing conditions will inform the microstructure remains a challenge due to the rapid solidification in laser powder bed fusion. This study uses in situ X-ray imaging and electron backscatter diffraction microscopy to demonstrate that the melt pool size, microstructure morphology, and elastic strain distribution is influenced by a combination of lattice geometry and laser processing conditions. These results indicate that within larger melt pools the local thermal gradients are sufficient to enable a columnar-to-equiaxed transition across the melt pool. Furthermore, the solidification mechanisms producing these microstructures are examined across the first 5 ms of melting and solidification, described via in situ high-speed X-ray imaging and mirrored via multiphysics simulation.

additive manufacturing↗

Distinct Melt Infusion Architectures of Antiperovskite Solid Electrolytes

Antiperovskite solid electrolytes are an emerging class of lithium‐ion conductors distinguished by their unusually low melting points, enabling scalable, low‐temperature processing routes not accessible to most solid electrolytes. In this work, we synthesize phase‐pure chloride (Cl), bromide (Br), and mixed halide (ClBr) variants of antiperovskites and investigate their ionic conductivities in both powder and hot‐pressed forms. Hot pressing significantly enhances conductivity across all compositions, while energy‐dispersive X‐ray spectroscopy (EDS) of the mixed halide system reveals halide surface migration during densification. We further investigate the melt‐infiltration behavior of these electrolytes into substrates relevant to solid‐state battery architectures, including Al and Cu current collectors, conventional NMC and LFP cathodes, and a foamed NMC cathode with a highly porous architecture. The foamed cathode enables deep and uniform electrolyte penetration, highlighting the role of electrode architecture in facilitating melt infiltration. Across all substrates, electrolyte halide chemistry strongly influences wetting behavior, penetration depth, and resulting microstructural morphology. Together, these results establish clear processing–structure relationships for melt‐infiltrated antiperovskite solid electrolytes and demonstrate how electrolyte chemistry and electrode architecture govern interfacial morphology during integration, providing practical guidelines for processing and structural design in solid‐state battery systems.

antiperovskite↗

Predicting Melt Curves of Energetic Materials Using Molecular Models

Here, in this work, the solid–liquid coexistence curves of classical fully flexible atomistic models of α-RDX and β-HMX were calculated using thermodynamically rigorous methodologies that identify where the free energy difference between the phases is zero. The free energy difference between each phase at a given state point was computed using the pseudosupercritical path (PSCP) method, and Gibbs–Helmholtz integration was used to evaluate the solid–liquid free energy difference as a function of temperature. This procedure was repeated for several pressures to determine points along the coexistence curve, which were then fit to the Simon–Glatzel functional form. While effective, this method is computationally expensive. An alternative approach is to compute the melting point at a single pressure via the PSCP method, and then use the Gibbs–Duhem integration technique to trace out the coexistence curve in a more computationally economical manner. Both approaches were used to determine the coexistence curve of α-RDX. The Gibbs–Duhem integration method was shown to generate a melt curve that is in good agreement with the PSCP-derived melt curve, while only costing ~10 % of the computational resources used for the PSCP method. For α-RDX, the predicted melting temperature increases significantly more for a given increase in pressure when compared to available experimental data.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Nanoscale interfacial melting enables bonding during high velocity microparticle impacts

Melting during high-velocity particle impact has been understood to be typically detrimental to bonding by lowering the strength at the interface and promoting rebound before solidification can occur. Here we establish a possible remedy to this challenge: by dramatically restricting the volume of molten material, its resolidification is accelerated, effectively forming a nanoscale, braze-type joint during impact. In-situ single particle impact imaging is combined with post-mortem structural and chemical analyses to reveal a regime where adhesion is governed not by extensive plastic deformation, but by the kinetics of melt layer resolidification. Furthermore, these findings redefine the role of melting in impact-based processes, establishing transient melting and rapid solidification as a viable strategy for engineering successful adhesion events.

Additive manufacturing↗

Detecting missing struts in metallic micro-lattices using high speed melt pool thermal monitoring

Metal lattices are an important class of cellular materials that offer great advantages by providing high-strength and lightweight structures as compared to bulk materials. Progress in additive manufacturing techniques has led to increased complexity in design and shape of produced objects and is greatly beneficial for the development of metallic lattice structures. However additive manufacturing of lattices suffers from unpredictable defect creation that can compromise its mechanical integrity. Although post-build inspection techniques can provide quality assurance of the process, accurate assessment can be technically challenging, time consuming and costly. In this work, we investigate the use of high-speed measurements of thermal emission from the melt pool to identify defective individual struts formed with a missing bottom half in an otherwise fully built lattice structure produced with laser powder bed fusion. Surprisingly, results indicate lower photodiode signal, suggesting colder melt pool surface temperature, when printing struts with missing bottom half as compared to nominal struts. Additional thermographic imaging and multi-physics simulations reveal that the low photodiode signal is accompanied by presence of hot spatters carrying heat away from detection and continuous avalanche of powder on the melt pool. Based on these observations, a method was developed to identify defective individual struts with missing bottom half in full built lattices. This prediction approach provides valuable insights about part quality which are important for process qualification and illustrates the utility of melt pool thermal emission monitoring for identifying specific defects introduced by laser powder bed fusion.

36 MATERIALS SCIENCE↗

Synthesis of precipitation-strengthened Al-Sc, Al-Zr and Al-Sc-Zr alloys via selective laser melting of elemental powder blends

Selective laser melting is used to create Al-1.5Sc, Al-1.5Zr and Al-0.75Sc-0.75Zr (at.%) alloys from blends of elemental Al, Sc, and Zr powders. This study investigates elemental alloying elements (Sc and Zr) which are high-melting and highly reactive, unlike previous work which focused on more concentrated elemental additions of lower-melting, lower-reactivity Cu and Si to aluminum. High-speed in situ synchrotron x-ray imaging and diffraction show that the 20–30 μm Al, Sc, and Zr powders fully melt and sufficiently mix in the molten state to create, on solidification, a homogeneous distribution of primary, micron-size L12 precipitates (Al 3 Sc, Al 3 Zr, and Al 3 (Sc,Zr), respectively) and nucleate micron-size Al matrix grains, as confirmed by SEM imaging of cross-sections. Here, a second laser pass, simulating a realistic additive-manufacturing build condition, fully remelts the initial volume which shows, after solidification, the same Al 3 (Sc,Zr) L1 2 primary micro-precipitates and very fine Al grains. After aging at 300–400°C, the alloys show large increases in hardness, consistent with an exceptionally high number density (1.4 × 10 24 m –3 ) and volume fraction (2.5%) of secondary Al 3 (Sc,Zr) nano-precipitates with a Sc-rich core and Zr-rich shell, as measured via atom-probe tomography.

36 MATERIALS SCIENCE↗

Dendrite-resolved, full-melt-pool phase-field simulations to reveal non-steady-state effects and to test an approximate model

In this report we study the epitaxial, columnar growth of (multiply oriented) dendrites/cells for a spot melt in a polycrystalline Al–Cu substrate using two-dimensional, phase-field, direct numerical simulations (DNS) at the full-melt-pool scale. Our main objective is to compare the expensive DNS model to a much cheaper but approximate “line” model in which a single-crystal phase-field simulation is confined to a narrow rectangular geometry. To perform this comparison, we develop algorithms that automatically extract quantities of interest (QoIs) from both DNS and line models. These QoIs allow us to quantitatively assess the assumptions in the line model and help us analyze its discrepancy with the DNS model. We consider four sets of heat source parameters, mimicking welding and additive manufacturing conditions, that create a combination shallow and deep melt pools. Our largest DNS simulation used 16K x 14K grid points in space. Our main findings can be summarized as follows. Under AM conditions, the QoIs of line models are in excellent agreement with the full DNS results for both shallow and deep melt pools. Under welding conditions, the primary spacing of the DNS model is smaller than the prediction of line model. We identify a geometric crowding effect that accounts for the discrepancies between the DNS and line models. We propose two potential mechanisms that determine the response of the microstructure to geometric crowding.

36 MATERIALS SCIENCE↗