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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Melt Pool characteristics on surface roughness and printability of 316L stainless steel in laser powder bed fusion

Purpose Surface quality and porosity significantly influence the structural and functional properties of the final product. This study aims to establish and explain the underlying relationships among processing parameters, top surface roughness and porosity level in additively manufactured 316L stainless steel. Design/methodology/approach A systematic variation of printing process parameters was conducted to print cubic samples based on laser power, speed and their combinations of energy density. Melt pool morphologies and dimensions, surface roughness quantified by arithmetic mean height (Sa) and porosity levels were characterized via optical confocal microscopy. Findings The study reveals that the laser power required to achieve optimal top surface quality increases with the volumetric energy density (VED) levels. A smooth top surface (Sa < 15 µm) or a rough surface with humps at high VEDs (VED > 133.3 J/mm 3 ) can serve as indicators for fully dense bulk samples, while rough top surfaces resulting from melt pool discontinuity correlate with high porosity levels. Under insufficient VED, melt pool discontinuity dominates the top surface. At high VEDs, surface quality improves with increased power as mitigation of melt pool discontinuity, followed by the deterioration with hump formation. Originality/value This study reveals and summarizes the formation mechanism of dominant features on top surface features and offers a potential method to predict the porosity by observing the top surface features with consideration of processing conditions.

Engineering↗
DOE OSTI2023

Corrosion behavior of Monofrax K-3 refractory in borosilicate-based model low activity waste glass melts

Owing to its good chemical and thermal durabilities at high temperatures, Monofrax K-3 refractory is widely used in nuclear waste vitrification as a lining material in melting vessels. However, the corrosion of K-3 refractory during the vitrification of nuclear waste is a serious problem because it affects the melter's safety, performance, and lifetime. Therefore, in the present study, we have focused on unearthing the impact of glass network formers, such as SiO 2 , B 2 O 3 , and Al 2 O 3 , in a model nuclear waste glass composition on the corrosion of Monofrax K-3 refractory. The corrosion tests have been performed per ASTM C621 at 1150°C for 5 days. The dimensional measurements on corroded K-3 refractory suggest that Al 2 O 3 and SiO 2 tend to reduce the refractory corrosion (neck loss), with the effect of Al 2 O 3 being significant. A corroded region on the K-3 refractory at the melt–refractory interface is observed. The corrosion occurs via a coupling of the melt infiltration induced by a capillary effect and the dissolution of Al, Mg, and Fe components from K-3 into the melt through chemical reactions. A Cr-rich layer is retained on the glass contact surface of the corroded K-3 refractory.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Melting and Ejecta Produced by High Velocity Microparticle Impacts of Steel on Tin

At sufficiently high velocities, a microparticle impacting a metal substrate can cause ejection of material from the substrate and impact-induced melting, both of which can result in erosion. Here, we directly image the impact of individual hard steel microparticles on soft tin substrates, at controlled impact velocities in the range of ~100 to 1000 m/s. By using scanning electron and laser scanning confocal microscopy, we characterize the surface morphology, depth, and volume of each impact crater. We observe a gradual onset of impact-induced melting in the craters, as well as the production of increasing amounts of ejecta from the target metal. By comparing measurements of impact and rebound velocity to an elastic-plastic model, we observe that at a high enough impact velocity, melting and ejection begin to consume additional kinetic energy beyond that expected by plastic deformation of the target material alone. By calculating the excess energy dissipation using this elastic-plastic model, we show that although this divergent behavior is associated with the onset of melting, the majority of the ejected volume must be solid rather than liquid.

Mechanics↗
DOE OSTI2022

The seeds and homogeneous nucleation of photoinduced nonthermal melting in semiconductors due to self-amplified local dynamic instability

Laser-induced nonthermal melting in semiconductors has been studied over the past four decades, but the underlying mechanism is still under debate. Here, by using an advanced real-time time-dependent density functional theory simulation, we reveal that the photoexcitation-induced ultrafast nonthermal melting in silicon occurs via homogeneous nucleation with random seeds originating from a self-amplified local dynamic instability. Because of this local dynamic instability, any initial small random thermal displacements of atoms can be amplified by a charge transfer of photoexcited carriers, which, in turn, creates a local self-trapping center for the excited carriers and yields the random nucleation seeds. Because a sufficient amount of photoexcited hot carriers must be cooled down to band edges before participating in the self-amplification of local lattice distortions, the time needed for hot carrier cooling is the response for the longer melting time scales at shorter laser wavelengths. This finding provides fresh insights into photoinduced ultrafast nonthermal melting.

42 ENGINEERING↗
DOE OSTI2020

Low Temperature Sequential Melting and Anion Retention in Simplified Low Activity Waste

This study seeks to understand the low temperature reactions of the salt phase that occur during the vitrification of Hanford Low Activity Waste (LAW). Salts (such as nitrates, sulfates, carbonates, halides, etc.) play a key role in these low temperature reactions as they sequentially melt, decompose, and volatilize during batch-to-glass conversion. To further understand these complex processes, simplified LAW melts containing oxyanion salts (sodium salts of carbonate, sulfate, and/or nitrate) and early melting glass formers (boric acid) have been evaluated using thermal analysis, infrared absorption spectroscopy, and X-ray diffraction. Results from this study indicate that the volatilization behavior of particular salts is influenced by the presence or absence of other salts. Here, NaNO 3 volatilization is decreased by the presence of Na 2 SO 4 . The addition of either Na 2 SO 4 or NaNO 3 to the system may enhance the volatilization of Na 2 CO 3 . In all cases, Na 2 SO 4 was retained after melting and was often found to be in two different crystalline phases upon quenching.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Sulfur speciation in dacitic melts using X-ray absorption near-edge structure spectroscopy of the S K -edge (S-XANES): Consideration of radiation-induced changes and the implications for sulfur in natural arc systems

Abstract The synchrotron technique of micro X-ray absorption near-edge structure spectroscopy at the sulfur K-edge (S-XANES) provides a unique opportunity to measure the proportion of different oxidation states of sulfur (S) in silicate glasses. Although applied extensively in the analysis of basaltic silicate glasses, few S-XANES studies have investigated variations in S oxidation states with fO2 in felsic silicate glasses. In addition, no study has systematically compared the S-XANES results obtained from the same samples at different photon flux densities to quantify the relationship between exposure time and changes in S speciation in silicate glass, as has been done for Fe and V. This study evaluates observed differences in S speciation measured in experimentally produced H2O-saturated dacitic glasses over a range of reducing to oxidizing conditions (from log fO2 = ΔFMQ-0.7 to ΔFMQ+3.3; FMQ is the fayalite-magnetite-quartz mineral redox buffer) and equilibrated at 1000 °C and 300 MPa. S-XANES spectra were collected at three different photon flux densities using three microspectroscopy beamlines. As is observed in S-XANES analyses of basaltic silicate glasses, beam-induced changes to the S6+/ΣS are observed as a function of photon flux density and beam exposure time. Our results demonstrate that silicate glasses of dacitic composition undergo beam-induced photo-reduction in samples equilibrated at ΔFMQ > +1.75 and photo-oxidation if equilibrated at ΔFMQ < +1. The time required to observe beam-induced changes in the spectra varies as a function of flux density, and our study establishes an upper photon density limit at ~1.0 × 1012 photons/µm2. The S6+/ΣS calculated from spectra collected below this absorbed photon limit at intermediate flux densities (~1–4 × 109 photons/s per µm2) are affected by beam damage, as no conditions were found to be completely free of beam-induced changes. However, the S6+/ΣS ratios calculated below the limit at intermediate flux densities are consistent with thermodynamic constraints, demonstrating that S6+/ΣS ratios calculated from S-XANES spectra can be considered reliable for estimating the oxygen fugacity. Our results carry important implications for the S budget of felsic magmas and dissolution mechanisms in evolved melts. While our results from all three flux densities show the presence of S4+ dissolved in relatively oxidized (ΔFMQ > +1.75) dacitic glass, even in the spectra exposed to the lowest photon densities, we are unable to rule out the possibility that the S4+ signal is the result of instantaneous X-ray irradiation induced beam damage using S-XANES alone. When our spectra are compared to S-XANES spectra from basaltic silicate glasses, important differences exist in the solubility of S2– and S6+ between dacitic silicate melts, pointing to differences in solubility mechanisms as melt composition changes. This study highlights the need for further investigation into beam damage systematics, presence of S4+, and the solubility mechanisms of different oxidation states of S as silicate melt composition changes.

Geochemistry & Geophysics↗
DOE OSTI2023

The effect of inhomogeneities in coal-based mesophase pitch on filament formation and melt spinning for carbon fiber

Mesophase pitch-based carbon fibers excel as high specific strength and modulus materials, but challenges in stable, continuous melt spinning processing are a serious limiting factor. Inhomogeneities in the pitch may result in flow instabilities that can lead to filament breakage. This work aims to characterize and offer mitigation strategies for the negative effects that inhomogeneities such as isotropic binder, gels, and other inclusions impart on melt spinning of mesophase pitch. The effect of inhomogeneities on spinning stability are analyzed using capillary rheometry, borescope imaging of elongating filaments, and filtration. With no filter, immediate blockage of the spinning capillary occurred. Improvement in melt spinning duration was observed when a porous metal filter (20 μm nominal pore size) was utilized, but no significant further improvement in spinning duration was found upon decreasing the filter nominal pores size to 10, 5 and 2 μm. Moreover, flow instabilities that disrupted melt spinning stability were observed by capillary rheometry when the size of included isotropic pitch domains were larger than approximately 10 μm. Resultant carbon fiber properties and SEM imaging of fracture surfaces are reported.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Optimization of Scrap Melting Using an Electric Arc in Steel Manufacturing

Steel industry is crucial to the national economy and security. Around 67% of crude steel in the U.S is produced in electric arc furnaces (EAF), which is energy intensive. Around 140 EAFs operate in the U.S., consuming about 8.6x10 7 MMBtu/year of electricity. One of major challenges for EAFs includes maximizing the efficiency of the electrical energy provided in the form of electric arcs to melt various scrap mixes. To address this issue, a computational fluid dynamics (CFD) methodology is chosen to analyze scrap melting using the electric arc. Due to complex furnace phenomena and the wide variety of potential scenarios, high performance computing (HPC) is essential to yield comprehensive and detailed CFD analyses and systematic parametric studies for optimized EAF operation. The objectives are to 1) simulate scrap melting using electric arc, 2) evaluate electrode/arc position for optimum scrap melting and 3) establish reduced order model for CFD data-base for fast model calculation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

The Melting Behavior of Hydrogen Direct Reduced Iron in Molten Steel and Slag: An Integrated Computational and Experimental Study

Direct reduced iron (DRI) and hot briquetted iron (HBI) are essential feedstocks for tramp element control in the electric arc furnace (EAF). Due to greenhouse gas (GHG) concerns related to CO2 emissions, hydrogen as a substitute for natural gas and a reductant in DRI production is being widely explored to reduce GHG emissions in ironmaking. This study examines the melting behavior of hydrogen DRI (H-DRI) pellets in the EAF containing low-carbon (0.1 wt.%) molten steel and molten slag. A computational heat transfer model was developed to predict the melting behavior of H-DRI pellets. To validate the model, a set of experimental laboratory simulations was conducted by immersing H-DRI in a molten steel bath and slag. The temperature history at the center of the pellet during melting and the shell thickness at different melting stages were utilized to validate the model. The simulation results agree with the experimental measurements of steel balls and H-DRI in different metallic molten steel and slag baths.

Materials Science↗
NASA NTRS1964

Integral coolant channels supply made by melt-out method

Melt-out method of constructing strong, pressure-tight fluid coolant channels for chambers is accomplished by cementing pins to the surface and by depositing a melt-out material on the surface followed by two layers of epoxy-resin impregnated glass fibers. The structure is heated to melt out the low-melting alloy.

Escher, W. J. D.↗
NASA NTRS1974

Melting relations of the Allende meteorite

The proportions of major oxides in the Allende carbonaceous chondrite after partial reduction are remarkably similar to those in possible mantle material of the earth. When heated, the Allende meteorite generates a sulfide melt, a ferrobasaltic melt, and olivine with or without pyroxene, over a wide pressure range (5 to 25 kilobar). The silicate melt contains more sodium and less titanium than lunar ferrobasalts. An aggregate of the Allende chondrite rich in calcium and aluminum produces silica-undersaturated, calcium-rich melt and spinel over a wide pressure and temperature range. It is suggested that the earth's core contains significant amounts of both nickel and sulfur and that a 3:2 mixture of Allende bulk sample and calcium- and aluminum-rich agregates is closer in major element abundances than either of these components to the average composition of the moon.

Seitz, M. G.↗
NASA NTRS1974

Reinvestigation of the olivine-spinel transformation in Ni2SiO4 and the incongruent melting of Ni2SiO4 olivine

The olivine-spinel transformation and the melting behavior of Ni2SiO4 were investigated over the PT ranges of 20-40 kbar, 650-1200 C, and 5-13 kbar, 1600-1700 C, respectively. It was confirmed that Ni2SiO4 olivine melts incongruently at high pressures and that it is a stable phase until melting occurs. The PT slope of the incongruent melting curve is approximately 105 bars/deg. The olivine-spinel transformation curve was shown to be a reversible univariant curve, and could be expressed by the linear equation P(bars) equals 23,300 + 11.8 x T(deg C). The transformation curve determined by Akimoto et al. (1965) is nearly parallel to that of the present work, but lies at pressures about 12% lower.

Ma, C.-B.↗
NASA NTRS1976

M551 metals melting experiment

The Metals Melting Skylab Experiment consisted of selectively melting, in sequence, three rotating discs made of aluminum alloy, stainless steel, and tantalum alloy. For comparison, three other discs of the same three materials were similarly melted or welded on the ground. The power source of the melting was an electron beam unit. Results are presented which support the concept that the major difference between ground base and Skylab samples (i.e., large elongated grains in ground base samples versus nearly equiaxed and equal sized grains in Skylab samples) can be explained on the basis of constitutional supercooling, and not on the basis of surface phenomena. Microstructural observations on the weld samples and present explanations for some of these observations are examined. In particular, ripples and their implications to weld solidification were studied. Evidence of pronounced copper segregation in the Skylab A1 weld samples, and the tantalum samples studied, indicates a weld microhardness (and hence strength) that is uniformly higher than the ground base results, which is in agreement with previous predictions. Photographs are shown of the microstructure of the various alloys.

Li, C. H.↗
NASA NTRS1976

Metal melting, joining, and alloying under weightlessness

During the Skylab mission experiments were conducted concerning the influence of weightlessness on molten metals and the solidification process. It was found that the absence of gravity-induced thermal convection and sedimentation modified the properties of the bulk melt. A metals melting experiment was conducted to study the behavior of metal melted by an electron beam and to evaluate the feasibility of joining metals in space. An exothermic brazing experiment investigated the spreading, mixing, and capillary flow of molten braze material. The containerless melting and solidification of small samples of several metals was studied in another experiment. A description is also given of a study of the directional solidification of solid solution alloys.

Snyder, R. S.↗
NASA NTRS1977

The Apollo 17 'melt sheet' - Chemistry, age and Rb/Sr systematics

Major, minor, and trace-element compositions, age data, and Rb/Sr systematics of Apollo 17 boulders have been compiled, and additional analyses performed on a norite breccia clast (77215) included in the Apollo 17, Station 7 boulder. The Apollo 17 boulders are found to be identical or nearly so in major, minor, and trace-element composition, suggesting that they all originated as an impact melt analogous to melt sheets found in larger terrestrial craters. The matrix dates (Ar-40/Ar-39) and Rb/Sr systematics available suggest that this impact melt formed by a single impact about 4 billion years ago. This impact excavated, shocked, brecciated, and melted norites, norite cumulates, and possibly anorthositic gabbros and dunites about 4.4 billion years old. The impact was likely a major one, possibly the Serenitatis basin-forming event.

Winzer, S. R.↗
NASA NTRS1978

The thermal history of the Manicouagan impact melt sheet, Quebec

Calculations for the heat transfer between superheated silicate melt and evenly dispersed 1-mm cold clasts indicate that most of the thermal gradients are smoothed out in 100 s and that the rate of equilibrium is sufficiently high so that clasts whose dissolution in the melt is slow may be preserved. The calculations also show the extent to which cold debris and clasts are melted. Calculations for cooling of the 200-m-thick melt sheet at Manicouagan suggest that complete crystallization takes 35 years at 10 m from the edge and 1600 years at the center.

Onorato, P. I. K.↗
NASA NTRS1977

Examination of the liquid line of descent of mare basalts in light of data from melt inclusions in olivine

Data on 226 melt inclusions and their host olivines (173 new analyses) are presented and interpreted in terms of general liquid lines of descent and olivine fractionation. The melt inclusions in olivine along with those in ilmenite and late-stage mesostasis in mare basalts define a complex trend. The trend is complicated by the effects of ilmenite, plagioclase, and pyroxene fractionation within the melt inclusions in olivine, the fact that most of the basalts were multiply saturated during olivine fractionation, and the phenomenon of late-stage silicate immiscibility. It is suggested that the first two factors can account for the observed marked divergence of the melt inclusion data from simple early olivine fractionation trends. The elimination of the effects of daughter mineral fractionation by homogenization experiments is considered.

Weiblen, P. W.↗
NASA NTRS1977

Compositional variation in late-stage differentiates in mare lavas, as indicated by silicate melt inclusions

Questions regarding an interpretation of data from silicate melt inclusions are considered, taking into account the fragmental nature of the record, the possible effects of cooling rate on late-stage melt composition, and the crystallization of the trapped melt. New data related to 484 new analyses are provided in a separate table. Textural and mineralogical features and bulk chemical composition for an overall characterization of late-stage differentiates are discussed. A description is presented of a grouping and recognition of rock types on the basis of late-stage inclusion analyses. Attention is given to the bimodality of potassium values and the delineation of differentiation trends. It is found that many of the problems in interpretation and much of the scatter found in the composition of silicate melt inclusions in lunar samples can be attributed to the incomplete nature of the record and to crystallization after trapping.

Roedder, E.↗