SEARCH · Engineering Papers
Results for “Melting”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Measurement of Dynamic Melting and Re-Crystallization of Shocked Metals
Explore the source record for details and available documents.
Additive Manufacturing of Miniaturized Peak Temperature Monitors for In-Pile Applications
Passive monitoring techniques have been used for peak temperature measurements during irradiation tests by exploiting the melting point of well-characterized materials. Recent efforts to expand the capabilities of such peak temperature detection instrumentation include the development and testing of additively manufactured (AM) melt wires. In an effort to demonstrate and benchmark the performance and reliability of AM melt wires, we conducted a study to compare prototypical standard melt wires to an AM melt wire capsule, composed of printed aluminum, zinc, and tin melt wires. The lowest melting-point material used was Sn, with a melting point of approximately 230 °C, Zn melts at approximately 420 °C, and the high melting-point material was aluminum, with an approximate melting point of 660 °C. Through differential scanning calorimetry and furnace testing we show that the performance of our AM melt wire capsule was consistent with that of the standard melt-wire capsule, highlighting a path towards miniaturized peak-temperature sensors for in-pile sensor applications.
Arctic sea ice albedo: Spectral composition, spatial heterogeneity, and temporal evolution observed during the MOSAiC drift
The magnitude, spectral composition, and variability of the Arctic sea ice surface albedo are key to understanding and numerically simulating Earth’s shortwave energy budget. Spectral and broadband albedos of Arctic sea ice were spatially and temporally sampled by on-ice observers along individual survey lines throughout the sunlit season (April–September, 2020) during the Multidisciplinary drifting Observatory for the Study of Arctic Climate (MOSAiC) expedition. The seasonal evolution of albedo for the MOSAiC year was constructed from spatially averaged broadband albedo values for each line. Specific locations were identified as representative of individual ice surface types, including accumulated dry snow, melting snow, bare and melting ice, melting and refreezing ponded ice, and sediment-laden ice. The area-averaged seasonal progression of total albedo recorded during MOSAiC showed remarkable similarity to that recorded 22 years prior on multiyear sea ice during the Surface Heat Budget of the Arctic Ocean (SHEBA) expedition. In accord with these and other previous field efforts, the spectral albedo of relatively thick, snow-free, melting sea ice shows invariance across location, decade, and ice type. In particular, the albedo of snow-free, melting seasonal ice was indistinguishable from that of snow-free, melting second-year ice, suggesting that the highly scattering surface layer that forms on sea ice during the summer is robust and stabilizing. In contrast, the albedo of ponded ice was observed to be highly variable at visible wavelengths. Notable temporal changes in albedo were documented during melt and freeze onset, formation and deepening of melt ponds, and during melt evolution of sediment-laden ice. While model simulations show considerable agreement with the observed seasonal albedo progression, disparities suggest the need to improve how the albedo of both ponded ice and thin, melting ice are simulated.
The Snow Albedo Evolution (SALVO) Campaign at the North Slope of Alaska Field Campaign Report
The springtime surface-albedo transition in the Alaskan Arctic, along with the forces that determine its duration and nature, was the focus of the Snow ALbedo eVOlution (SALVO) campaign. The SALVO team investigated the reasons and durations of the stages of spring melt, during which albedo values decrease from 0.8 to 0.1, signifying the year’s largest and most significant radiative energy change. SALVO II (2022, 2024) built on findings from the successful SALVO I (2019) melt season campaign and previous research on the melt transition period conducted by Grenfell and Perovich (2004). SALVO used the ARM NSA observatory, thus aligning with a core principle of the ARM Decadal Vision to “provide comprehensive and impactful field measurements to support scientific advancement of atmospheric process understanding.” SALVO fieldwork was conducted in the spring near the ARM NSA Central Facility in Utqiagvik, Alaska (Figure 1). Comprehensive data sets were collected in 2019, 2022, and 2024, which included spectral and broadband albedos, snow and meltwater depths, snow stratigraphy, snow grain size data, and aerial imagery. In April of each project year, before the snow began to melt, we established survey lines at three or four locations: inland tundra at NSA E12, coastal tundra at the NSA C1 site, Elson Lagoon, and offshore on the Chukchi Sea sea ice (2022 only). We set up a 200-meter-long line, marked every five meters, to enable repeated measurements of surface albedo and snow depth at each location. During most site visits, the SALVO II team dug at least one snow pit to assess the characteristics of the vertical snow layers, including the types and sizes of snow grains, snow density, and the distribution of liquid water. We evaluated the characteristics of flowing or pooled water at the bottom of the snowpack. Watching snow melt in the Arctic has been compared by some to being as exciting as watching paint dry, but it is far more exciting and dynamic than that. Initially, changes happen slowly while the snow cover remains above 80%, but then reductions in the albedo of the landscape, from about 0.8 to 0.4, combined with rising spring temperatures, begin to accelerate the melt. It happens so quickly that no matter how hard the field team works, they cannot keep up with documenting the changes. At first, liquid water is scarce—only a few wet layers of snow in the snowpack. But then, water becomes ubiquitous, transporting melt energy and creating an extremely heterogeneous albedo and melt landscape. At the end of each field season, the SALVO team is exhausted, relieved to see the snow gone, and joyful to play in the melt ponds on the sea ice under the midnight sun. Overall, the 2024 SALVO field campaign was a highlight, reflecting numerous lessons learned from 2019 and 2022. Daily measurements were taken more than 10 times at each site, resulting in a comprehensive time series of snow conditions and albedo. The team deployed using snowmachines and then on foot when snowmachine travel was no longer permitted on the melting tundra. Instrument mounts and packaging were optimized for quick deployment, regardless of the mode of transportation.
The role of föhn winds in eastern Antarctic Peninsula rapid ice shelf collapse
Ice shelf collapse reduces buttressing and enables grounded glaciers to contribute more rapidly to sea-level rise in a warming climate. The abrupt collapses of the Larsen A (1995) and B (2002) ice shelves on the Antarctic Peninsula (AP) occurred, at least for Larsen B, when long-period ocean swells damaged the calving front and the ice shelf was inundated with melt lakes that led to large-scale hydrofracture cascades. During collapse, field and satellite observations indicate föhn winds were present on both ice shelves. Here we use a regional climate model and machine learning analyses to evaluate the contributory roles of föhn winds and associated melt events prior to and during the collapses for ice shelves on the AP. Föhn winds caused about 25 % ± 3 % of the total annual melt in just 9 d on Larsen A prior to and during collapse and were present during the Larsen B collapse, which helped form extensive melt lakes. At the same time, the off-coast wind direction created by föhn winds helped melt and physically push sea ice away from the ice shelf calving fronts that allowed long-period ocean swells to reach and damage the front, which has been theorized to have ultimately triggered collapse. Collapsed ice shelves experienced enhanced surface melt driven by föhn winds over a large spatial extent and near the calving front, whereas SCAR inlet and the Larsen C ice shelves are affected less by föhn-wind-induced melt and do not experience large-scale melt ponds. These results suggest SCAR inlet and the Larsen C ice shelves may be less likely to experience rapid collapse due to föhn-driven melt so long as surface temperatures and föhn occurrence remain within historical bounds.
Formation, cooling history and age of impact events on the IIE iron parent body: Evidence from the Miles meteorite
Most iron meteorites formed in planetary cores during differentiation, but the IIE iron meteorites have chemical and physical features that are inconsistent with this origin. By combining mineral chemistry, mineral modes and three-dimensional petrography, we reconstruct the bulk chemistry of the felsic silicate-bearing Miles IIE iron meteorite and demonstrate that the silicate inclusion compositions are similar to partial melts produced experimentally from an H chondrite composition. We use the reconstructed bulk composition, mineralogy and thermodynamic modelling to show that melting above ~ 1200°C under reducing conditions formed metal (Fe-Ni alloy) and felsic silicate partial melts. Upon cooling, the melts crystallized Mg-rich pyroxenes, Na- and K-rich feldspars, and tridymite. Importantly, this mechanism enriches cosmochemically volatile elements (i.e., those with a 50% condensation temperature of ~430–830°C, like Na and K) to the level found in the felsic silicate inclusions. The presence of crystallographically disordered srilankite (only stable above 1160°C) and an absence of Widmanstätten texture require both high peak temperatures and rapid cooling, which cannot be explained by core formation. Instead, they point to small melt volumes, a transient heat pulse, and small thermal mass, and imply efficient physical segregation of silicate and metallic melts through buoyancy separation followed by rapid cooling that arrested the separation of metal and silicate liquid phases. In situ 207 Pb/ 206 Pb age of 4542.3 ± 4.0 Ma in Zr-oxide and phosphate minerals dates the melting event that formed the silicate inclusions. This age aligns with the earliest ages found in other IIE iron meteorite silicates and requires a heating event ~25 million years after the solar system formed. We found 39 Ar/ 40 Ar ages of 3495 ± 52 Ma (low-T) and 4303 ± 7 Ma (high-T) in a K-feldspar grain, with the 3495 Ma age aligning with later thermal events recorded in other IIE iron meteorites. Dating reveals the complex petrogenetic and thermal history of Miles and the IIE iron meteorites. This is the first IIE iron meteorite found to record evidence of heating at 4.5 and 3.5 Ga likely from impact events. We propose that high-velocity impact(s) into an iron-rich, porous chondritic parent body at ~4.54 Ga produced immiscible metal and silicate melts that cooled rapidly and trapped low density silicate inclusions within high density metal. Other IIE irons that formed at lower peak temperatures (900–1000°C) contain chondritic silicate inclusions and relict chondrules, supporting this conceptual model. In conclusion, this petrogenesis is consistent with thermodynamic modelling, experimental data and the wide range of peak temperatures and cooling rates observed in the IIE iron meteorites.
Nanoparticle-enabled increase of energy efficiency during laser metal additive manufacturing
The low energy efficiency of the laser metal additive manufacturing (AM) process is a potential sustainability concern for large-scale industrial production. Explicit investigation of the energy efficiency for laser melting requires the direct characterization of melt pool dimension and vapor depression, which is very difficult due to the opaque nature of the molten metal. Here we report the direct observation and quantification of effects of the TiC nanoparticles on the vapor depression and melt pool formation during laser powder bed fusion (LPBF) of Al6061 by in-situ high-speed high-energy x-ray imaging. Based on the quantification results, we calculated the laser melting energy efficiency (defined here as the ratio of the energy needed to melt the material to the energy delivered by the laser beam) with and without TiC nanoparticles during LPBF of Al6061. Here the results show that adding TiC nanoparticles into Al6061 leads to a significant increase of laser melting energy efficiency (114% increase on average, 521% increase under 312 W laser power, 0.4 m/s scan speed). Systematic property measurement, simulation, and x-ray imaging studies enable us, for the first time, to identify that three mechanisms work together to enhance the laser melting energy efficiency: (1) adding TiC nanoparticles increases the absorptivity; (2) adding TiC nanoparticles decreases the thermal conductivity, and (3) adding TiC nanoparticles enables the initiation of vapor depression and multiple reflection at lower laser power (i.e., lowers the laser power threshold for keyholing). The method and mechanisms of using TiC nanoparticles to increase the laser melting energy efficiency during LPBF of Al6061 we reported here may guide the development of feedstock materials for more energy efficient laser metal AM.
Effect of network connectivity on behavior of synthetic Broborg hillfort glasses
There is wide industrial interest in developing robust models of long-term (>100 years) glass durability. Archeological glass analogs, glasses of similar composition, and alteration conditions to those being tested for durability can be used to evaluate and inform such models. Two such analog glasses from a 1500-year-old vitrified hillfort near Uppsala, Sweden have previously been identified as potential analogs for low concentration Fe-bearing aluminosilicate nuclear waste glasses. However, open questions remain regarding the melting environment from which these historic glasses were formed and the effect of these conditions on their chemical durability. A key factor to answering the previous melting and durability questions is the redox state of Fe in the starting and final materials. Past work has shown that the melting conditions of a glass-forming melt may influence the redox ratio value (Fe +3 /ΣFe), a measure of a glass's redox state, and both melting conditions and the redox ratio may influence the glass alteration behavior. Synthetic analogs of the hillfort glasses have been produced using either fully oxidized or reduced Fe precursors to address this question. In this study, the melting behavior, glass transition temperature, oxidation state, network structure, and chemical durability of these synthesized glass analogs is presented. Resulting data suggests that the degree of network connectivity as impacted by the oxidation state of iron impacted the behavior of the glass-forming melt but in this case does not affect the chemical durability of the final glass. Glasses with a lower degree of melt connectivity were found to have a lower viscosity, resulting in a lower glass transition temperature and softening temperature, as well as in a lower temperature of foam onset and temperature of foam maximum. This lower degree of network connectivity most likely played a more significant role in accelerating the conversion of batch chemicals into glass than the presence of water vapor in the furnace's atmosphere. Future work will focus on using the results from this work with outcomes from other aspects of this project to evaluate long-term glass alteration models.
Assessment of Readout Techniques for Passive Monitors
This fiscal year (FY) 2023 report on passive temperature sensors covers two main objectives: to demonstrate that the optical dilatometer can successfully process disc shaped silicon carbide (SiC) temperature monitors (TMs), and to demonstrate proof of concept for using the capacitance readout method to read printed melt wires. The SiC objective was successfully met by annealing and analyzing, via optical dilatometry, all eight 3-mm SiC discs provided by the Nuclear Science User Facilities (NSUF) Idaho State University (ISU) Nanostructured Steels for Enhanced Radiation Tolerance (N SERT) experiment, which was irradiated at Idaho National Laboratory (INL)’s Advanced Test Reactor (ATR). Per the ISU N SERT experiment, capsule 1 (KGT 3828 1 and KGT 3828-2) had a design temperature of 300°C +/- 50°C and an exposure of 2 dpa +/- 10%; capsule 2 (KGT 4600 and KGT 4609) had a design temperature of 300°C +/- 50°C and an exposure of 6 dpa +/- 10%; capsule 3 (KGT 4639 C and KGT 4639-D) had a design temperature of 500°C +/- 50°C and an exposure of 6 dpa +/- 10%; and capsule 4 (KGT 3841 3 and KGT 3841 4) had a design temperature of 500°C +/- 50°C and an exposure of 2 dpa +/- 10%. The target exposure rates, in dpa, are the neutron damage for various types of nanostructured steels. All but three SiC TMs (KGT 4600, KGT 4639 D, and KGT 3841 4) revealed averaged peak irradiation temperatures that fell within the design temperature ranges. The three SiC TMs that did not fall within the design temperatures ranges were at least 100°C below that target temperature. Furthermore, SiC TM KGT 3841 C revealed two irradiation regimes: one closer to the 300°C design temperature, and the other closer to the 500°C design temperature. Also, all the SiC TMs’ averaged peak irradiation temperatures came in anywhere between 20°C and 240°C below the irradiation temperatures predicted by the thermal models. This showed the optical dilatometry method to be a reliable and less time intensive process for determining averaged peak irradiation temperatures from passive SiC TMs such as rods and discs. Under the Advanced Sensors and Instrumentation (ASI) program in FY-23, Boise State University (BSU) proposed to demonstrate proof of concept for using a capacitance readout technique applicable to printed melt wires; however, they were stymied by the complexity of the capacitance readout method. In support of the BSU work, INL developed an additively manufactured (AM) ceramic package for encapsulating the new melt wires. Inks were synthesized at BSU that used new protocols rather than following previously established protocols implemented at INL, and testing of various temperatures was conducted at BSU to evaluate the melting behaviors of the printed melt wires. The result was that the capacitance readout technique showed promise but also created more challenges than originally anticipated. For example, the tin ink synthesized at BSU showed unusual melting behaviors that did nothing to enhance the performance of the final printed melt wire prototype in terms of the capacitance readout method. To make the proof of concept work when applied to the printed melt wires, the ASI program would need to invest further resources and time. Consequently, the program is not planning to continue this proof of concept work in FY-24, based on the progress and findings achieved in FY-23.
Passive Temperature Sensors for Nuclear Applications
Thermocouples are generally used to provide real-time temperature indications in instrumented tests performed at material and test reactors. Passive temperature monitors, such as Silicon Carbide (SiC) and melt wires, may be included in such tests as an independent technique of detecting peak temperatures experienced during irradiation. In less expensive static (drop-in) capsule tests, which have no leads attached for real-time data transmission, melt wires, and SiC temperature monitors (TMs) are essentially the only possibility for peak temperature indication. A melt wire involves placing materials (wires) of a known composition and melting temperature in a test. An inventory is maintained at Material Science Laboratory (MSL) for melt wires ranging in temperatures from 30°C to 1500°C. Unfortunately, melt wires are limited in that it can only detect whether a single temperature is or is not exceeded (melt wire melted or not). SiC TMs, which can also be used to detect peak irradiation temperatures, are advantageous because a single monitor can allow to determine the peak temperature reached within a relatively broad range (100 – 1200°C) resulting in accuracies within ±20°C. Irradiation temperature is determined by measuring a property change after isochronal annealing or during a continuously monitored annealing process using specialized equipment at MSL. Recent research has produced a passive monitor known as sublime temperature monitor. This passive sensor has the capability of recording temperature gradients and pinpointing exactly where a temperature is located along that gradient. Long measurement lengths are achieved with very high accuracy in the location of desired temperature measurements (±2 mm over a 1 m span); however, this sensor has not been deployed in a nuclear reactor. This article will focus only on passive temperature sensors currently being researched and implemented under the Advanced Sensors and Instrumentation (ASI) program at Idaho National Laboratory (INL).
Three-Dimensional Heat Flux and Thermal Analysis of Angled Tungsten Samples on DIII-D
ITER-grade tungsten and dispersoid-strengthened tungsten samples with the top surface angled at ~15° towards the incident plasma flux were exposed to 9 H-mode discharges with edge-localized modes (ELMs) in the lower divertor of DIII-D tokamak using the Divertor Material Evaluation System (DiMES). Surface damage included cracking and flaking of material on the two samples farthest away from the plasma strike point, and significant melting of the two samples closest to the strike point. Heat flux and thermal analysis tools new to DIII-D have been applied to better understand this material response and to help optimize the exposure conditions for future experiments. SMITER field-line tracing simulations based on IRTV data and EFIT equilibria estimate an average inter-ELM perpendicular heat flux, 𝑞⊥,𝑖nter−𝐸LM , on the angled surfaces of 10.1 – 19.6 MW/m² for a majority of the 9 discharges, increasing to 15.6 – 24.5 MW/m² for the single, higher-power shot where samples melted. Fast camera data showed shallow intra-ELM melting and re-solidification, which transitioned to bulk inter-ELM melting with melt motion in the 𝐽⃗ 𝑥 𝐵⃗ direction. About 50% of the protruding volume of the most affected sample was displaced via melt-motion. SIERRA thermal modeling software was able to reproduce an onset time of melting consistent with fast camera data and final sample conditions, within < 200 ms. Maximum surface temperatures of 3122 K and 2787 K are estimated for the samples farthest away from the strike point, while the closest samples achieve melting at 4067 ms and 4750 ms into the ~5000 ms plasma exposure. A +10% increase in both the SMITER 𝑞⊥,𝑖nter−𝐸LM calculations and the estimated ELM heat loads 𝑞⊥, 𝐸LM was required to achieve this result, which is within the uncertainty of the diagnostic data but likely accounts for non-ideal geometry effects plus other physics uncertainties not included in this first iteration of modeling. This work provided valuable estimates of the 3D temperature evolution to help better understand the observed surface morphology and internal recrystallization of samples, which are discussed in detail in a complementary manuscript [1]. Benchmarking efforts with more diagnosed DIII-D experiments are underway to further refine the SMITER and SIERRA models for DiMES. Future use of these tools will enable researchers to precisely target heat flux exposure conditions in DIII-D to test, but not exceed, the thermomechanical limitations of novel plasma-facing materials.
Ultrafast x-ray detection of low-spin iron in molten silicate under deep planetary interior conditions
The spin state of Fe can alter the key physical properties of silicate melts, affecting the early differentiation and the dynamic stability of the melts in the deep rocky planets. The low-spin state of Fe can increase the affinity of Fe for the melt over the solid phases and the electrical conductivity of melt at high pressures. However, the spin state of Fe has never been measured in dense silicate melts due to experimental challenges. We report detection of dominantly low-spin Fe in dynamically compressed olivine melt at 150 to 256 gigapascals and 3000 to 6000 kelvin using laser-driven shock wave compression combined with femtosecond x-ray diffraction and x-ray emission spectroscopy using an x-ray free electron laser. The observation of dominantly low-spin Fe supports gravitationally stable melt in the deep mantle and generation of a dynamo from the silicate melt portion of rocky planets.
Eu speciation in apatite at 1 bar: An experimental study of valence-state partitioning by XANES, lattice strain, and Eu/Eu* in basaltic systems
Abstract Partition coefficients for rare earth elements (REEs) between apatite and basaltic melt were determined as a function of oxygen fugacity (fO2; iron-wüstite to hematite-magnetite buffers) at 1 bar and between 1110 and 1175 °C. Apatite-melt partitioning data for REE3+ (La, Sm, Gd, Lu) show near constant values at all experimental conditions, while bulk Eu becomes more incompatible (with an increasing negative anomaly) with decreasing fO2. Experiments define three apatite calibrations that can theoretically be used as redox sensors. The first, a XANES calibration that directly measures Eu valence in apatite, requires saturation at similar temperature-composition conditions to experiments and is defined by: ( E u 3 + ∑ E u ) Apatite = 1 1 + 10 - 0.10 ± 0.01 × l o g ( f o 2 ) - 1.63 ± 0.16 . The second technique involves analysis of Sm, Eu, and Gd in both apatite and coexisting basaltic melt (glass), and is defined by: ( Eu E u * ) D Sm × Gd = 1 1 + 10 - 0.15 ± 0.03 × l o g ( f o 2 ) - 2.46 ± 0.41 . The third technique is based on the lattice strain model and also requires analysis of REE in both apatite and basalt. This calibration is defined by ( Eu E u * ) D lattice strain = 1 1 + 10 - 0.20 ± 0.03 × l o g ( f o 2 ) - 3.03 ± 0.42 . The Eu valence-state partitioning techniques based on (Sm×Gd) and lattice strain are virtually indistinguishable, such that either methodology is valid. Application of any of these calibrations is best carried out in systems where both apatite and coexisting glass are present and in direct contact with one another. In holocrystalline rocks, whole rock analyses can be used as a guide to melt composition, but considerations and corrections must be made to either the lattice strain or Sm×Gd techniques to ensure that the effect of plagioclase crystallization either prior to or during apatite growth can be removed. Similarly, if the melt source has an inherited either a positive or negative Eu anomaly, appropriate corrections must also be made to lattice strain or Sm×Gd techniques that are based on whole rock analyses. This being the case, if apatite is primary and saturates from the parent melt early during the crystallization sequence, these corrections may be minimal. The partition coefficients for the REE between apatite and melt range from a maximum DEu3+ = 1.67 ± 0.25 (as determined by lattice strain) to DLu3+ = 0.69 ± 0.10. The REE partition coefficient pattern, as observed in the Onuma diagram, is in a fortuitous situation where the most compatible REE (Eu3+) is also the polyvalent element used to monitor fO2. These experiments provide a quantitative means of assessing Eu anomalies in apatite and how they be used to constrain the oxygen fugacity of silicate melts.
Reduced Atmospheres of Post-impact Worlds: The Early Earth
Impacts may have had a significant effect on the atmospheric chemistry of the early Earth. Reduced phases in the impactor (e.g., metallic iron) can reduce the planet's H 2 O inventory to produce massive atmospheres rich in H 2 . While previous studies have focused on the interactions between the impactor and atmosphere in such scenarios, we investigate two further effects: (1) the distribution of the impactor's iron inventory during impact between the target interior, target atmosphere, and escaping the target; and (2) interactions between the post-impact atmosphere and the impact-generated melt phase. We find that these two effects can potentially counterbalance each other, with the melt–atmosphere interactions acting to restore reducing power to the atmosphere that was initially accreted by the melt phase. For a ~10 22 kg impactor, when the iron accreted by the melt phase is fully available to reduce this melt, we find an equilibrium atmosphere with H 2 column density ~10 4 moles cm –2 (pH 2 ~ 120 bars, X H2 ~ 0.77), consistent with previous estimates. However, when the iron is not available to reduce the melt (e.g., sinking out in large diameter blobs), we find significantly less H 2 (7 × 10 2 – 5 × 10 3 moles cm –2 , pH 2 ≲ 60 bars, X H2 ≲ 0.41). These lower H 2 abundances are sufficiently high that species important to prebiotic chemistry can form (e.g., NH 3 , HCN), but sufficiently low that the greenhouse heating effects associated with highly reducing atmospheres, which are problematic to such chemistry, are suppressed. The manner in which iron is accreted by the impact-generated melt phase is critical in determining the reducing power of the atmosphere and resolidified melt pool in the aftermath of impact.
Manufacturing of HEAs at Different Scales
The knowledge gained from melting and processing of high-entropy alloys (HEAs) at different scales is discussed with respect to melt parameters and characteristics. The melting techniques considered are button melting, vacuum induction melting (VIM) and electroslag remelting (ESR). While VIM produces HEAs with enhanced chemical homogeneity, particularly after being subjected to a homogenization heat treatment, and refined grain structure, other concerns arise from elemental contaminants associated with industrial-grade melt stock. Although ESR of the VIM product decreases the concentration of tramp elements, the narrow melt range typically found in HEAs or medium entropy alloys was found to decrease the melt efficiency. The experiments presented were performed on ingots ranging from 100 g to 75 kg.
Effect of glass forming additives on low-activity waste feed conversion to glass
A significant effort was invested in the past to develop and refine mathematical models that relate the composition of nuclear waste glasses with their properties, such as viscosity, electrical conductivity, or chemical durability. However, less attention has been paid to the formulation of the melter feed itself, such as the chemical form and the particle size of the glass forming and modifying additives (GFMA), which have a significant effect on the feed-to-glass conversion process during melting. To address this issue, we systematically changed the mineral composition of a simulated low-activity waste melter feed and inspected its melting behavior. When substituting minerals with corresponding oxides and hydroxides, we found that different alumina sources (kyanite, gibbsite, boehmite, or corundum) had the strongest effect on the feed melting process, whereas the sources of Ca, Mg, and Zr had little effect. Further, the x-ray diffraction analysis showed that the alumina sources differ in their dissolution kinetics: early dissolving alumina sources, such as gibbsite (Al(OH) 3 ) and boehmite (AlO(OH)), increase the transient glass-forming melt viscosity at early stages, when gases still evolve, causing extended foaming, whereas alumina sources that dissolve at high temperatures, such as kyanite (Al 2 SiO 5 ) and corundum (Al 2 O 3 ), keep the transient glass-forming melt viscosity low and lead to a faster foam collapse. Using viscosity-composition relationship to estimate the viscosity of transient glass-forming melts in the primary foaming range, we found that the primary foam began to collapse at 360 to 800 Pa s, and fully collapsed between 65 and 260 Pa s. This result agrees with our previous studies, according to which the glass-forming melt viscosity at the cold cap foam bottom ranged from 24 to 85 Pa s.
A dynamic volumetric heat source model for laser additive manufacturing
Melt pool scale models of laser powder bed fusion (LPBF) offer insights into the process-structure-property relationships in additive manufacturing (AM). These models often neglect physical phenomena such as vapor cavity formation and fluid mechanics to reduce computational demands. Instead, volumetric heat source models are used to represent the effects that these phenomena have on the predicted melt pool dimensions. Generally, the dimensions and effective absorption of the volumetric heat source are calibrated to reproduce melt pool dimensions observed in metallographic cross sections taken from single-track experiments on bare plate. However, the transient nature of LPBF often deviates the melt pool dimensions from the assumed steady-state conditions of single-track experiments, motivating the need for a volumetric heat source model that more generally considers the dynamic relationship between melt pool shape and laser-material interactions. Here, we introduce a two-parameter volumetric heat source model that integrates several existing models into a generalized mathematical expression, providing independent control over the radial heat distribution via the parameter k and the volumetric shape of the heat source via the parameter m. This parameterization enables the calibration of melt pool shape predictions through simultaneous adjustment of these parameters, while keeping the radial heat source dimensions consistent with the experimental spot size (D4σ) and constraining the heat source depth and absorption to physically derived expressions for cavities. Consequently, the proposed volumetric heat source model adapts to changes in the local melt pool conditions due to scanning strategy and part geometry by dynamically adjusting the heat source depth and absorption. We demonstrate the capabilities of the proposed model through comparisons with a collection of experiments from the Additive Manufacturing Benchmark (AMBench).