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At least 541 records · Page 30

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NASA NTRS2020

Decay of the Snow Cover Over Arctic Sea Ice From ICESat‐2 Acquisitions During Summer Melt in 2019

From the onset of melt in early June, corresponding declines in Ice, Cloud, and Land Elevation Satellite‐2 (ICESat‐2) freeboard and surface albedo can be seen over the entire Arctic sea ice cover. In the 2019 summer, area‐averaged freeboard decreased from 34 cm prior to melt to a minimum of 12 cm in August while the area‐averaged albedo decreased from ~0.7 to 0.38 for the same period. Calculations using ICESat‐2 freeboards and modeled ice thickness from Pan‐Arctic Ice Ocean Modeling and Assimilation System (PIOMAS) give area‐averaged snow depths ranging from 17 cm prior to melt to 3 cm in August over seasonal ice and from 34 to 4 cm over multiyear ice. Mean rates of snow ablation (including evaporation) in mid‐June were as high as 2 cm/day, comparable to field records from other years. Increases in freeboard after mid‐August in the high latitude (>80°N) multiyear ice cover, north of the Greenland coast, are likely due to earlier freeze‐up and snow accumulation in these regions with shorter melt seasons.

R Kwok↗

NASA NTRS2021

Molecular dynamics simulations of ultrafast radiation induced melting at metal–semiconductor interfaces

Metal–semiconductor contacts in silicon carbide (SiC) diodes endure damages at the interface when exposed to harsh radiation environments. Due to the rapid rise in temperature and ultrafast cooling that follows the radiation impact, the structural properties of the materials can be altered through melting, recrystallization, and amorphization. A detailed understanding of the material failure modes at the interface is lacking, specifically at the nanoscale. We use molecular simulations to investigate the ultrafast melting at tungsten (W)–SiC interfaces following radiation damage and apply deep learning techniques to track the transient evolution of the local molecular structures. We show that W near the radiation track undergoes melting and, eventually, most of it recrystallizes with a noticeable degree of undercooling, while SiC is rendered permanently amorphous. The observation of local undercooling in W films is important as it can affect the device performance even before the bulk melting temperature of the material is reached. We also show that at high temperatures, the interface undergoes a fracture-like failure. The results presented here are significant in understating the different failure modes of SiC diode materials.

Ashwin Ravichandran↗

NASA NTRS2021

Melting and Crystallization Behavior of CaO-MgO-Al2O3-SiO2 Silicates Relevant to Turbine Engine Applications

The melting and crystallization behavior of four quaternary CaO-MgO-Al2O3-SiO2(CMAS) silicates were investigated. The CaO:SiO2 ratios of these systems were based on various terrestrial sources of ingested particles relevant to gas turbine engine operating environments. Melting behavior was characterized using differential scanning calorimetry, and high temperature intrinsic crystallization products were determined by furnace heat treatments of the glasses at 1200°C, 1300°C, and 1400°C. The silicates exhibited a wide range of melting temperatures from ~1240°C up to ~1500°C, with most of the compositions exhibiting incongruent melting behavior. High temperature crystallization products included CaSiO3,CaAl2Si2O8, Ca2MgSi2O7, and Ca(Mg,Al)Si2O6, although SiO2 was the only crystalline phase observed at 1400°C.

Jamesa L. Stokes↗

NASA NTRS2024

The H-poor nature of incompletely melted planetesimals: The view from acapulcoites and lodranites

The abundance of H in planetary building blocks is of fundamental importance for constraining the evolution of the terrestrial planets. It is commonly assumed that chondrites are the principal sources of Earth’s H; however, recent studies have suggested that primitive achondrites and achondrites may retain a small complement of H. There are few constraints on the H budgets of primitive achondrites, which represent the transition from unmelted to melted planetesimals, but prior work suggests that bulk parent body H contents are several orders of magnitude lower than typical chondritic values. Therefore, to provide further constraints on H retention during the transition from unmelted to melted planetesimals, we have measured the H contents of olivine, orthopyroxene, clinopyroxene, and plagioclase from a suite of acapulcoite-lodranite clan meteorites. Acapulcoite-lodranite clan meteorites represent the “prototypical” primitive achondrite parent body and have bulk major element compositions more akin to the Earth than previously studied primitive achondrites (e.g., the ureilites). We find that the H 2 O contents of olivine (∼5–12 µg/g H 2 O), orthopyroxene (∼3–10 µg/g H 2 O), and clinopyroxene (∼5–8 µg/g H 2 O) are broadly similar, while plagioclase (∼2.5–5 µg/g H 2 O) tends to be offset to lower values. Using a simple, single-stage batch-melting model, we calculate a preferred maximum acapulcoite-lodranite parent body H 2 O content of 38 µg/g, which is similar to other estimates for primitive achondritic and achondritic parent bodies. Furthermore, assuming chondrite-like precursor materials, our data are consistent with efficient loss of H prior to or during the onset of melting of early-formed planetesimals. This requires that Earth’s H-budget was dominated by building blocks that underwent minimal thermal processing.

Primitive achondrite↗

NASA NTRS2024

Enhancing Consistency of Microphysical Properties of Precipitation Across the Melting Layer in the Dual-Frequency Precipitation Radar Data

Stratiform rain and the overlying ice play crucial roles in Earth's climate system. From a microphysics standpoint, water mass flux primarily depends on two variables: particles' concentration and their mass. The Dual-frequency Precipitation Radar (DPR) on the Global Precipitation Measurement mission core satellite is a spaceborne instrument capable of estimating these two quantities through dual-wavelength measurements. In this study, we evaluate bulk statistics on the ice particle properties derived from dual-wavelength radar data in relation to the properties of rain underneath. Specifically, we focus on DPR observations over stratiform precipitation, characterized by columns exhibiting a prominent bright band, where the melting layer can be easily detected. Our analysis reveals a large increase in the retrieved mass flux as we transition from the ice to the rain phase in the official DPR product. This observation is in disagreement with our expectation that mass flux should remain relatively stable across the bright band in cold-rain conditions. To address these discrepancies, we propose an alternative retrieval algorithm that ensures a gradual transition of Dm (mean mass-weighted particle melted-equivalent diameter) and the precipitation rate across the melting zone. This approach also helps in estimating bulk ice density above the melting level. These findings demonstrate that DPR observations can not only quantify ice particle content and their size above stratiform rain regions but also estimate bulk density, provided uniform conditions that minimize uncertainties related to partial beam filling.

radar measurements from space↗

NASA NTRSDate not supplied

Calcium and Magnesium Distribution Between Sulfide and Silicate Melts: Thermodynamic Modeling and Insights into Mercury's Mantle-Crust Differentiation

Mercury stands out as the terrestrial planet with the lowest degree of oxidation among all planets of our solar system. It is characterized by a high abundance of sulfur, which is expected to replace oxygen in silicate melts. This sulfur enrichment could lead to sulfide saturation in its mantle, potentially resulting in the formation of sulfides rich in calcium and magnesium. Utilizing experimental data from the literature, we constructed a thermodynamic model to explore the partitioning of calcium and magnesium between sulfide and silicate melts. This model aims to improve our comprehension of the chemical equilibria driving the process of mantle-crust differentiation on Mercury. Our models indicate that increased temperature, decreased pressure, and low concentrations of iron, oxygen, and carbon within the sulfide phase, along with low sulfur concentrations in the silicate phase, favor calcium’s partitioning into the sulfide. Additionally, magnesium partitioning into the sulfide melt is favored with decreased pressure, decreased temperature, low concentrations of iron and calcium within the sulfide, and low concentrations of sulfur within the silicate. Our results suggest that up 9.4% and 5.6% Ca and Mg, respectively, can be present in sulfides equilibrated with sulfide-saturated silicate melts during mantle-crust differentiation. Further investigation will focus on the distribution of sulfide phases within the mantle and crust to better constrain Mercury’s internal structure.

Taylor McCombs↗

DOE OSTI2020

Method for achieving sustained anisotropic crystal growth on the surface of a silicon melt

An apparatus for growing a crystalline sheet from a melt includes a cold block assembly. The cold block assembly may include a cold block and a shield surrounding the cold block and being at an elevated temperature with respect to that of the cold block, the shield defining an opening disposed along a surface of the cold block proximate a melt surface that defines a cold area comprising a width along a first direction of the cold block, the cold area operable to provide localized cooling of a region of the melt surface proximate the cold block. The apparatus may further include a crystal puller arranged to draw a crystalline seed in a direction perpendicular to the first direction when the cold block assembly is disposed proximate the melt surface.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Lignin-based polymers with enhanced melt extrusion ability

A solid polymer blend material comprising: (i) lignin; and (ii) a polyamide having a melting point of no more than 240° C. and which is below the decomposition temperature of the lignin; wherein said lignin is homogeneously dispersed in said polyamide. Methods for producing the blend material are also described. Methods for producing objects made of the blend material by melt extrusion are also described, comprising: (a) melt blending components (i) and (ii) to form a polymer blend in which components (i) and (ii) are homogeneously blended, wherein the polymer blend exhibits a melt viscosity of no more than 2000 Pa·s at a shear rate of 100-1000 s −1 and when heated to a temperature of no more than 240° C.; and; (b) forming an object made of said polymer blend material.

Naskar, Amit K.↗

DOE OSTI2024

Computational Methods for Multi-Physics Simulation of Melting in Steelmaking

Iron and steel production accounts for approximately 8% of global carbon dioxide (CO) emissions. Pathways to decarbonize include replacing fossil fuels in iron ore reduction and electrifying other steelmaking processes. Iron pellets produced by hydrogen, called Hydrogen Direct Reduced Iron (HDRI), have property differences from those produced using conventional DRI processes. These differences may impact melting in electric arc furnaces (EAF) and other downstream processes. The physical properties of iron pellets vary significantly with temperature during heating, complicating predictions of their behavior. In this project, we seek to develop an integrated simulation, including the fluid flow and convective thermal transport around the pellet particle. We also examine conduction and phase changes within the particle as they impact the melting process. We use adaptive mesh refinement (AMR) to resolve both the changing size of the particle and the complex physics of the interaction between the pellet and the surrounding fluid. We base our simulations on the AMReX-incflo module, which allows large-scale Navier-Stokes simulation while resolving the changing particle size during melting. As we advance our numerical tools, we anticipate an improved understanding of the dynamics of HDRI melting, which will, in turn, accelerate the adoption of low-carbon technologies in the steelmaking industry.

AMReX↗

DOE OSTI2026

Insights into mixing of non-isothermal multi-polymer melts for complex plastics recycling

Catalytic recycling or upcycling of plastics is often limited not by catalyst performance, but by transport, arising from highly viscous, non-Newtonian polymer melts. In this work, we develop a reactor-scale framework that integrates rheological measurements, constitutive modeling, computational fluid dynamics (CFD), and experiments to quantify mixing, heat transfer, and dispersion in surrogate hydrocarbon melts representing mixed plastics systems. Temperature- and shear rate-dependent viscosity of low-density polyethylene (LDPE) and high-density polyethylene (HDPE) is measured to create two surrogate polymers (PLD and PHD) that capture the dominant shear-thinning flow behavior while neglecting strong elastic effects, enabling tractable simulation of non-isothermal, polymer-melt mixing using a Carreau-Arrhenius generalized Newtonian framework. Three-dimensional CFD simulations are employed to evaluate impeller performance in PLD using mixing time, cavern volume, thermal uniformity, and interfacial area for regimes in which viscoelastic effects are not dominant. We show that magnetic stir bars commonly used in lab-scale studies produce large thermal gradients (~60 °C) and poor mixing, even under idealized power delivery and polymer flow conditions. In contrast, close-clearance anchor impellers achieve near-isothermal operation, reduce mixing times by up to 5×, and provide >90% active circulation volume. We further demonstrate that, at low pseudo-Deborah number (De*), motor power requirements can be predicted directly from shear rate-dependent rheology using the Carreau-Arrhenius framework, enabling rational selection of operating conditions. Extension to surrogate immiscible multi-polymer systems based on PLD and PHD shows that interfacial area is highly sensitive to operating conditions and impeller design, with coaxial anchor-turbine configurations enhancing dispersion by up to 4 × .

Close-clearance impellers↗

DOE OSTI2022

Effect of melt shearing on D -mannitol crystal twisting in the presence of small molecule and macromolecular additives

Here, many molecular crystals grow as twisted lamellae from the melt when the driving force is high, but the mechanisms governing the spontaneous formation of helicoidal crystallites are varied and those operative in particular cases are difficult to identify. Polyvinylpyrrolidone (PVP) induces the crystallization of D-mannitol as banded spherulites comprised of twisted fibrils emanating radially from spherulite nucleation centers. The molecular weight of the PVP phase affects the twisting pitch, P, (rotation of the crystallite by 180°), in D-mannitol thin films crystallized from the melt. At a relatively high crystallization temperature (T c =130°C), P was sensitive to the PVP molecular weight, ranging from 390±20 μm for D-mannitol films incorporating 15 wt% 10 kDa PVP to 20±3 μm for the same weight of 1300 kDa PVP. Magnitudes of complex viscosities, |η*|, of D-mannitol/PVP melts measured via small-amplitude oscillatory shearing were strongly dependent on the PVP molecular weight, but were not correlated to P(T). Instead, P was sensitive to the dynamic PVP chain conformation during D-mannitol crystallization. Under steady torsional shear, P decreased from~30 μm to~8μm with increasing shear rates from 0.01 to 100 s -1 for D-mannitol films crystallized at 130°C in the presence of 15 wt% 10 or 1300 kDa PVP. Shear forces decrease the entanglement density of polymer chains while orienting the chains along the stream lines of the viscometric flow, indicating that the conformations of macromolecular additives can affect the pitch of banded spherulites. By contrast, P in D-mannitol twisted by D-sorbitol was independent of shear rate.

36 MATERIALS SCIENCE↗

DOE OSTI2025

LionGlass™: A low‐melting, carbonate‐free alternative to soda lime silicate glass

LionGlass™ is Penn State University's patent-pending alumino-silicophosphate glass compositional family that offers, for the first time, a viable low-melting, carbonate-free alternative to soda lime silicate glass by (a) lowering the melting temperature by up to 400°C compared to soda lime silicate glass and (b) eliminating the use of carbonate batch materials. The viscosity curve of LionGlass is shifted downward in temperature compared to soda lime silicate glass, enabling melting at much lower temperatures. LionGlass also has significantly improved resistance to crack initiation compared to soda lime silicate glass. Other properties, such as thermal expansion coefficient and optical dispersion curve, are comparable to those of traditional soda lime silicate glass.

Lion-Glass↗

DOE OSTI2022

Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 μm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.

36 MATERIALS SCIENCE↗

NASA NTRS2017

Comparison of Passive Microwave-Derived Early Melt Onset Records on Arctic Sea Ice

Two long records of melt onset (MO) on Arctic sea ice from passive microwave brightness temperatures (Tbs) obtained by a series of satellite-borne instruments are compared. The Passive Microwave (PMW) method and Advanced Horizontal Range Algorithm (AHRA) detect the increase in emissivity that occurs when liquid water develops around snow grains at the onset of early melting on sea ice. The timing of MO on Arctic sea ice influences the amount of solar radiation absorbed by the ice-ocean system throughout the melt season by reducing surface albedos in the early spring. This work presents a thorough comparison of these two methods for the time series of MO dates from 1979through 2012. The methods are first compared using the published data as a baseline comparison of the publically available data products. A second comparison is performed on adjusted MO dates we produced to remove known differences in inter-sensor calibration of Tbs and masking techniques used to develop the original MO date products. These adjustments result in a more consistent set of input Tbs for the algorithms. Tests of significance indicate that the trends in the time series of annual mean MO dates for the PMW and AHRA are statistically different for the majority of the Arctic Ocean including the Laptev, E. Siberian, Chukchi, Beaufort, and central Arctic regions with mean differences as large as 38.3 days in the Barents Sea. Trend agreement improves for our more consistent MO dates for nearly all regions. Mean differences remain large, primarily due to differing sensitivity of in-algorithm thresholds and larger uncertainties in thin-ice regions.

sea ice↗

DOE OSTI2025

Effect of laser melt schedule on the microstructure of additively manufactured IN718 Superalloy

Laser powder bed fusion (L-PBF) has enabled the fabrication of geometrically complex metallic structures and components that are challenging to producing using conventional manufacturing approaches. The site-specific and far from equilibrium thermal conditions of L-PBF offer the potential to facilitate multi-length scale design of structure and properties across the atomic-through macro-levels. However, L-PBF systems face scalability challenges due to throughput constraints. Laser rotary powder bed fusion (L-RPBF) systems are being investigated as a solution to enhance the deposition rates compared to conventional L-PBF. Rotary systems also offer additional flexibility for controlling the time structure of melting through laser interleaving on alternating layers. Here, in this study, IN718 test samples were printed using single-laser or interleaved dual-laser configuration in a L-RPBF system to investigates the effect of process settings and melt-interleaving on as-fabricated microstructure. The microstructural evolution, such as grain size and crystallographic texture, was assessed by determining variations in the melt-pool shapes. Laser interleaving leads to a reduction in average grain size compared to single laser by ∼ 40 % at high power (400 W) and by ∼36 % at medium power (370 W). Results presented here identify key challenge for obtaining uniform microstructures and barriers for the broader adoption of high-deposition rate L-RPBF.

Dual-laser↗

DOE OSTI2023

Melt pool instability detection using coaxial photodiode system validated by in-situ X-ray imaging

A co-axial photodiode monitoring system with high temporal resolution has been integrated into a proven test bench enabling synchronized side-view high speed X-ray imaging of melt pool dynamics and top-view spectral emission characterization of the melt pool. Here, this setup enables direct observation of melt pool phenomena and correlation between the two monitoring systems which can be directly scaled to commercial systems. The work demonstrates a 92% detection rate in keyhole collapse phenomena related to defect generation in SLM. Furthermore, the impact of gas flow on monitoring signals is studied to understand the fundamental importance of gas flow in commercial systems.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Temperature and Composition Dependence Modeling of Viscosity and Electrical Conductivity of Low-Activity Waste Glass Melts

The development of models that accurately relate the properties of a glass melt to its temperature and composition is important for glass formulation, melter control, and modeling the melt flow, refractory corrosion, and production rate. Using a database consisting of more than 4,000 data points measured between 900 °C and 1250 °C for over 600 unique low-activity waste glass compositions, we developed models for the melt viscosity and electrical conductivity. Models based on the Gaussian process regression approach outperformed models based on the Vogel–Fulcher–Tammann equation according to four standard metrics and yielded reliable prediction intervals. The models found primarily linear effects between properties and individual components, except for the effect of the Na 2 O mass fraction on the electrical conductivity. The effects were found to be consistent with current theories on physical processes involved with those properties.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Dual X-ray computed tomography-aided classification of melt pool boundaries and flaws in crept additively manufactured parts

In metal additive manufacturing (AM), understanding the process-structure-performance relationships requires a combination of multi-scale characterization techniques that allows for the measurement of the melt pool shape and boundary and classifying various defects and flaws in the AM parts. Such approaches can be destructive, only 2D in nature, or have a small field of view and can be complex to co-register and analyze. Here, in this work, we present a non-destructive 3D inspection technique that employs dual-energy X-ray computed tomography (XCT) along with a model-based iterative reconstruction (MBIR) and a new segmentation algorithm. The proposed approach and algorithm are not only capable of classifying and quantifying flaws such as pores, cracks, and inclusions, but they also allow for the extraction of microstructural features such as melt pool boundaries (MPB) and melt pool regions (MPR), that can help understand process-structure-performance relationships for alloys under study. As an exemplar application, we employed the method for characterization of an additively manufactured aluminum alloy crept under tensile stress at 300 °C for 1064 h. Our results demonstrate high quality segmentation and classification of various flaws and MPB and MPR, for the first time, using 3D X-ray CT inspection. The delineated MPB and MPR in the crept samples reveal the preferential growth paths of cracks that formed during creep deformation. The technique was used for successfully quantifying the characteristics (number of defects, their density, volume fraction, etc.) of the manufacturing-induced pores and creep-induced cracks, which is necessary to better understand the creep failure mechanisms of the material.

36 MATERIALS SCIENCE↗