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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Assessing Melting and Solid–Solid Transition Properties of Choline Chloride via Molecular Dynamics Simulations

Choline chloride (ChCl) is used extensively as a hydrogen bond donor in deep eutectic solvents (DESs). However, determining its melting properties experimentally is challenging due to decomposition upon melting, leading to widely varying literature values. Accurate melting properties are crucial for understanding the solid–liquid phase behavior of ChCl-containing DESs. Here, we employ molecular dynamics simulations to compute the phase transitions of ChCl, testing a variety of atomistic force fields. We find that the results are sensitive to the choice of force field, but a melting temperature of 627 K and a melting enthalpy of 7.8 kJ/mol seem most reasonable, in good agreement with some literature values. Furthermore, we suggest these as the likely melting properties of ChCl, though the results are tentative due to limited experimental data for the liquid ChCl phase.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Microscopic changes governing melting anisotropy: Real-time nanosecond x-ray diffraction

To understand the microscopic origins governing melting anisotropy, in-situ x-ray diffraction (XRD) measurements were obtained in aluminum single crystals shocked along $\langle$100$\rangle$ and $\langle$110$\rangle$ to stresses below and above the melting threshold for each orientation. XRD results and analysis for the two orientations showed significant differences in the microstructure prior to the melting threshold stresses, demonstrating the key role of deformation induced microstructure – in addition to temperature and pressure – on the melting transition. As a result, our findings make a strong case for reconsidering theoretical approaches to melting, specifically for dislocation mediated melting, in shock compressed solids.

crystal melting↗
DOE OSTI2021

Melting of magnesium oxide up to two terapascals using double-shock compression

Constraining the melting behavior of magnesium oxide, a major constituent of gaseous and rocky planets, is key to benchmarking their evolutionary models. Using a double-shock technique, we extended the MgO melt curve measurements to 2 TPa; this is twice the pressure achieved by previous melting experiments on any material. A temperature plateau is observed between 1218 and 1950 GPa in the second shock states, which is attributed to latent heat of melting. At 1950 GPa, the measured melting temperature is 17,600 K, 17% lower than recent theoretical predictions. Furthermore, the melting curve is steeper than that of MgSiO 3 , indicating that MgO is likely solid in the interior of Saturn-sized gas giants and extra-solar super-Earth planets.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Melting Behavior of Conventional and Hydrogen-Reduced DRI in a Simulated EAF Steel Bath

The melting behavior of carbon-free direct reduced iron (DRI) produced by hydrogen reduction has been investigated in a simulated electric arc furnace (EAF) melting environment. A testing apparatus was created to document the melting rates under various bath conditions in slag and steel. This investigation is specific to pellets melted in a steel bath. A model was developed to simulate the shell growth and melting rate of a non-reactive DRI pellet in molten steel. Data acquired from preliminary experiments are utilized to validate the model. This investigation sheds light on the potential effects of melting hydrogen-reduced DRI in the EAF.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effects of an External Magnetic Field on Keyhole Mode Laser Melting of 316 Stainless Steel

Keyhole-mode laser melting is an efficient method for joining or cutting large, thick components, but controlling keyhole depth and fluctuations has remained challenging. Applying an external magnetic field can control melt pool flows and indirectly influence keyhole morphology and dynamics. The induced Lorentz force, comprising Seebeck and damping components, plays a crucial role in the melt pool dynamics, depending on temperature gradient, flow rates, and magnetic field orientation and magnitude. This research investigates the effects of an external magnetic field on keyhole behavior during laser spot melting of 316 stainless steel using synchronized high-speed synchrotron X-ray and thermal imaging. Findings revealed that a longitudinal magnetic field (120 mT) increased keyhole depth but exacerbated lateral fluctuations, resulted in a 20% increase in the melt pool temperature gradient and a 27% decrease in cooling rate. Conversely, a transverse magnetic field (760 mT) reduced keyhole depth and improved porosity formation. The findings suggest that a decrease in keyhole depth correlates with a decrease in fluctuations, and vice versa. These insights enhance understanding of external magnetic fields’ impact on laser melting, with implications for improving part quality.

Alamdari, Aslan Bafahm [The Ohio State Univ., Colu↗
DOE OSTI2021

Through a glass darkly: In-situ x-ray computed tomography imaging of feed melting in continuously fed laboratory-scale glass melter

his study describes the first direct in-situ 3-D observation of a steady-state melting process by imaging a laboratory-scale slurry-fed glass melter in operation by x-ray computed tomography. Features of the reacting glass-feed, the foam layer underneath, and cavities in the glass melt pool are reconstructed in three-dimensional images. A slurry pool formed in a deep central caldera of dense dried feed, which penetrated into the glass melt. Slurry overflow from the caldera led to fast-dried and highly porous feed structure. A thin layer of foam separated the caldera from the melt. Bubbles ?5-15 mm in diameter were seen to grow beneath the reacting feed and move through the melt to escape at the edge. Pore morphology is benchmarked against computed tomography scans of a pellet of reacting simulated waste glass feed, and evolved gas analysis describes the gases generated as a function of temperature. Cooling artifacts are imaged and compared to previous studies of quenched cold caps. Detailed understanding of processes occurring during the conversion process in and below the reacting feed layer is necessary for the development of representative models of the melting process.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High-Pressure Melting Experiments of Fe 3 C and a Thermodynamic Model of Fe-C Liquids for the Earth's Core

Melting experiments of Fe 3 C were conducted to 85 GPa in laser-heated diamond anvil cells with in situ X-ray diffraction and post-experiment textural observation. From the determined pressure-temperature conditions of the melting curve for Fe 3 C, together with literature data on the melting point of diamond and eutectic point of the system Fe-Fe 3 C/Fe 7 C 3 under high pressures, we established a self-consistent thermodynamic model for high-pressure melting of the system Fe-C including the mixing parameters for liquids. The results show that mixing of Fe and C liquids is negatively nonideal from 1 bar to the pressure at the center of the Earth. The departure from ideal mixing becomes progressively larger with increasing pressure, which leads to greatly stabilized liquids under core pressures. The modeled carbon content in eutectic melts under core pressures is 3.3–4.4 wt%. From the Gibbs free energy, we derived an internally consistent parameters for Fe-C outer cores which included the crystallizing points at their bottoms, isentropic thermal profiles, and densities and longitudinal seismic wave speeds (Vp). While the addition of carbon in excess of the eutectic melt composition effectively reduces the density of iron liquid, the Vp of iron liquid is not greatly changed. Therefore, the low density and high Vp of PREM relative to pure iron cannot be reconciled by an Fe-C liquid. Therefore, the Earth's core cannot be approximated by the system Fe-C and should include another light element.

58 GEOSCIENCES↗
DOE OSTI2025

Subglacial Discharge Effects on Antarctic Ice‐Shelf Basal Melt and the Southern Ocean in a Global, Coupled Ocean—Sea‐Ice Model

Subglacial freshwater from beneath Antarctica enters the ocean at depth, enhancing ice-shelf melting and affecting Southern Ocean properties. To study these effects in an Antarctic-wide context, we use a continental-scale subglacial hydrology model that calculates grounding line freshwater flux for a global, coupled ocean—sea-ice model. We find that subglacial discharge impacts melt rates primarily through continental shelf temperature modification, contrasting with findings from regional studies that do not permit large-scale adjustments. The consequence is that Antarctic melt rates scale with subglacial discharge more strongly than inferred from regional studies. We also find that the addition of buoyancy at depth facilitates heat upwelling to the surface, resulting in higher sea ice volume downstream of cold ice shelves and lower sea ice volume downstream of warm ice shelves. This highlights the drawbacks of simplifications in previous global studies that deposit Antarctic meltwater at the ocean surface and find uniform ocean surface cooling and sea-ice growth. While the patterns we find are robust, we conclude that the addition of subglacial discharge at present-day rates has a small effect on basal melt rates, hydrography, and sea ice. However, stronger discharge can have significant effects and can even accelerate a shift from low to high melting for ice shelves close to such a tipping point. Finally, the importance of feedbacks between enhanced cavity overturning and continental shelf conditions poses a complication for parameterizing subglacial discharge effects on melting for ice-sheet projections that do not include a coupled ocean component.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Melting point of iron at high pressure: An assessment of uncertainties and effect of electronic temperature

An accurate calculation of the melting point of iron at various pressures in the Earth's core is important for understanding the core structure, geodynamo, and the Earth's history. Previous studies have assessed the melt line of iron at these extreme conditions using various experimental measurement techniques as well as both ab initio and classic molecular dynamics simulations. However, experimental measurements have uncertainties up to several hundred Kelvin, and inconsistencies remain among simulation results. Here in this work, we propose an iterative framework that couples density functional theory (DFT) calculations and molecular dynamics simulations performed using an ensemble of interatomic potentials to assess the effect of electronic temperature on the melting point. We systematically validate the potentials by comparing lattice constants and phonon dispersion curves at 0 K and enthalpy differences between liquid and HCP, FCC, BCC phases of iron close to the melt line at 300 GPa with DFT. Our results show that HCP iron melts at 6144 K (at 300 GPa), BCC phase is thermodynamically unstable, and FCC is metastable at this temperature. The melting points of FCC and BCC phases at 300 GPa are 5858 and 5647 K, respectively.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

High pressure melt line of nickel using a generalized embedded atomic method potential

As the second most abundant metal in the Earth's core, nickel plays an important role in determining the structure and temperature of the Earth's core. Yet, the melt line of Ni at pressures corresponding to the Earth's core has not been explored in the literature. Many previous experimental and simulation efforts have reported the melting point of Ni at pressures below 100 GPa, but there exist large discrepancies, most of which have persisted due to various experimental and simulation bottlenecks in handling extreme pressure and temperature conditions. We adopted the generalized embedded atom method, which overcomes the limitations of existing interatomic potentials, to probe phase stability and phase boundaries of Ni at pressures between 50 and 500 GPa. Further, the potential was validated by comparing the cold curves, phonon dispersion curves, and enthalpies of fusion with ab initio density functional theory calculations. Our analysis shows that face centered cubic (FCC) is stable, and the hexagonal close packed (HCP) and body centered cubic (BCC) phases are metastable close to the melt line. Melting temperatures at different pressures were obtained from two-phase co-existence simulations and take the following functional form: $T$ m = $1969.23+19.15P-0.012P$ 2 . In contrast to iron, differences between the melting points of the stable and metastable phases of Ni are less than 250 K at 300 GPa, and the difference in melting points of the metastable BCC and HCP phases changes sign at 500 GPa, which implies that the phase transition mechanisms during solidification can be very complex.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Laser melting modes in metal powder bed fusion additive manufacturing

In laser powder bed fusion additive manufacturing of metals, extreme thermal conditions create many highly dynamic physical phenomena such as vaporization and recoil, Marangoni convection, and protrusion and keyhole instability. Collectively however, the full set of phenomena is too complicated for practical applications and, in reality, the melting modes are used as a guideline for printing. With increasing local material temperature beyond the boiling point, the mode can change from conduction to keyhole. These mode designations ignore laser-matter interaction details but in many cases are adequate to determine the approximate microstructures and hence the properties of the build. To date, no consistent, common, and coherent definitions have been agreed upon because of historic limitations in melt pool and vapor depression morphology measurements. Here, we distinguish process-based definitions of different melting modes from those based on postmortem evidence. The latter are mainly derived from the transverse cross-sections of the fusion zone, whereas the former come directly from time-resolved x-ray imaging of melt pool and vapor depression morphologies. These process-based definitions are more strict and physically sound, and they offer new guidelines for laser additive manufacturing practices and create new research directions. Further, we highlight the significance of the keyhole, which substantially enhances the laser energy absorption by the melt pool. Recent studies strongly suggest that stable-keyhole laser melting enables efficient, sustainable, and robust additive manufacturing. The realization of this scenario demands the development of multiphysics models, signal translations from morphology to other feasible signals, and in-process metrology across platforms and scales.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Melting and crystallization peculiarities in Cd0.50Mn0.50Te solid solutions

We investigated melting and crystallization processes of Cd0.50Mn0.50Te. Using differential thermal analysis (DTA) we studied the solid-liquid equilibrium temperature range, the temperature dependence of the volume fraction of the solid phase in the melt, and crystallization peculiarities. We observed that changing a dwell temperature from 1346 to 1354 K results in an increase of the crystallization temperature of the Cd0.50Mn0.50Te melt. Since the melt is in a semi-liquid state, its crystallization occurs over a solid-phase domain. It was found that a slightly overheated Cd0.50Mn0.50Te melt (up to 10 K) crystallizes more slowly than more overheated melts, and that the Cd0.50Mn0.50Te solid solutions are in a semi-liquid state in the temperature range of 1338 – 1354 K.

Kopach, Oleh↗
DOE OSTI2024

Swirls and scoops: Ice base melt revealed by multibeam imagery of an Antarctic ice shelf

Knowledge gaps about how the ocean melts Antarctica’s ice shelves, borne from a lack of observations, lead to large uncertainties in sea level predictions. Using high-resolution maps of the underside of Dotson Ice Shelf, West Antarctica, we reveal the imprint that ice shelf basal melting leaves on the ice. Convection and intermittent warm water intrusions form widespread terraced features through slow melting in quiescent areas, while shear-driven turbulence rapidly melts smooth, eroded topographies in outflow areas, as well as enigmatic teardrop-shaped indentations that result from boundary-layer flow rotation. Full-thickness ice fractures, with bases modified by basal melting and convective processes, are observed throughout the area. This new wealth of processes, all active under a single ice shelf, must be considered to accurately predict future Antarctic ice shelf melt.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Effects of Particle Size Distribution with Efficient Packing on Powder Flowability and Selective Laser Melting Process

The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by a revolution powder analyzer). The effects of PSDs on the selective laser melting (SLM) process are identified by using in-situ high-speed X-ray imaging to observe the melt pool dynamics during the melting process. The results show that the powder beds made of powders with dense packing ratios exhibit larger build height during laser melting. The effects of PSD with efficient packing on powder flowability and selective laser melting process revealed in this work are important for understanding process uncertainties induced by feedstock powders and for designing mitigation approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Energetics of surface melt in West Antarctica

We use reanalysis data and satellite remote sensing of cloud properties to examine how meteorological conditions alter the surface energy balance to cause surface melt that is detectable in satellite passive microwave imagery over West Antarctica. This analysis can detect each of the three primary mechanisms for inducing surface melt at a specific location: thermal blanketing involving sensible heat flux and/or longwave heating by optically thick cloud cover, all-wave radiative enhancement by optically thin cloud cover, and föhn winds. We examine case studies over Pine Island and Thwaites glaciers, which are of interest for ice shelf and ice sheet stability, and over Siple Dome, which is more readily accessible for field work. During January 2015 over Siple Dome we identified a melt event whose origin is an all-wave radiative enhancement by optically thin clouds. During December 2011 over Pine Island and Thwaites glaciers, we identified a melt event caused mainly by thermal blanketing from optically thick clouds. Over Siple Dome, those same 2011 synoptic conditions yielded a thermal-blanketing-driven melt event that was initiated by an impulse of sensible heat flux and then prolonged by cloud longwave heating. The December 2011 synoptic conditions also generated föhn winds at a location on the Ross Ice Shelf adjacent to the Transantarctic Mountains, and we analyze this case with additional support from automatic weather station data. In contrast, a late-summer thermal blanketing period over Pine Island and Thwaites glaciers during February 2013 showed surface melt initiated by cloud longwave heating and then prolonged by enhanced sensible heat flux. One limitation thus far with this type of analysis involves uncertainties in the cloud optical properties. Nevertheless, with improvements this type of analysis can enable quantitative prediction of atmospheric stress on the vulnerable Antarctic ice shelves in a steadily warming climate.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Operando synchrotron X-ray analysis of melt pool dynamics in an Al-Sn immiscible alloy

The melt flow in an Al-50vol.% Sn immiscible alloy, produced by single-track laser melting of Al and Sn elemental powders, was studied in real time. High-speed synchrotron X-ray imaging was used to track Al and Sn liquids’ movements, and also to examine elemental distributions in the laser tracks, complimented by electron microscopy after solidification. Key aspects, including melt pool geometry, keyhole instability, and flow dynamics (flow pattern and velocity), were examined using digital image analysis. Relatively deeper melt pools formed at 400 W and 300 mm/s exhibited greater stability, with smooth surfaces, consistent outward flow, and minor vortices near the keyhole. In contrast, shallower pools produced at higher scanning speeds (>500 mm/s) demonstrated greater instability with increased surface waviness, and stronger velocity fluctuations, leading to numerous micro-vortices and increased Al-Sn heterogeneity. Velocity scale estimations, supported by experimental observations, examined the roles of vapour pressure, Marangoni effect, buoyancy, inertial, and surface tension forces in the flow. The results revealed that vapour pressure and mechanical waves dominated at high scanning speeds (shallow pools), while Marangoni forces were equally significant in deep pools at lower speeds (300 mm/s). Buoyancy was found to have minimal impact in both cases. Furthermore, the interaction between inertial and surface tension forces played a critical role in determining the degree of waviness of the pools’ surfaces. These findings offer valuable insights into melt pool dynamics during laser processing of immiscible alloys and other metallic systems using elemental powders, and provide guidance for developing high-fidelity computational fluid dynamics models.

immiscible alloys↗
DOE OSTI2022

The solubility of titanite in silicate melt determined from growth and dissolution experiments

The solubility of titanite (CaTiSiO 5 ) in Si-rich melts was measured experimentally through growth experiments at 800–1000 °C, 0.5–1.0 GPa, log fO 2 ~ CCO–0.8, t = 72–168 h, and H 2 O = 0 to 4 wt.%, and in dissolution experiments at 925–1300 °C, 0.8 GPa, t = 18–118 h, and H 2 O = 1–10 wt.% in a piston-cylinder apparatus. Run product glasses in growth experiments were homogeneous, and iron loss suppressed ilmenite crystallization. Saturation concentrations in dissolution experiments were estimated by fitting measured diffusion profiles. Titanite solubility increases with increasing temperature and melt composition parameter \(M = {\text{ molar }}\left( {{\text{Na }} + {\text{ K }} + {\text{ 2Ca}}} \right)/\left( {{\text{Al }} \times {\text{ Si}}} \right)\) . Multiple linear regression of glass composition data from growth and dissolution experiments ( n = 29) plus 39 experiments from the LEPR database (Hirschmann et al. 2008 ) yielded the titanite solubility equation (adj. r 2 = 0.95): \(\left( {TiO_{2} } \right)^{melt} \left( {wt.\% } \right) = 0.978 \times M + 0.0048 \times T\left( K \right){-}5.90\) . This model correctly predicted undersaturation in 95% of 2344 experiments from the LEPR database that did not have titanite or rutile. Application to natural rocks yields saturation temperatures that are similar to independent temperature estimates. Finally, this equation should be useful for constraining the temperatures of titanite-saturated melts, for determining whether titanite saturation in magmatic source regions is likely, and for determining when titanite can crystallize and begin to exert an influence on melt geochemistry.

58 GEOSCIENCES↗
DOE OSTI2024

Deep-learning based artificial intelligence tool for melt pools and defect segmentation

Accelerating fabrication of additively manufactured components with precise microstructures is important for quality and qualification of built parts, as well as for a fundamental understanding of process improvement. Accomplishing this requires fast and robust characterization of melt pool geometries and structural defects in images. This paper proposes a pragmatic approach based on implementation of deep learning models and self-consistent workflow that enable systematic segmentation of defects and melt pools in optical images. Deep learning is based on an image-to-image translation–conditional generative adversarial neural network architecture. An artificial intelligence (AI) tool based on this deep learning model enables fast and incrementally more accurate predictions of the prevalent geometric features, including melt pool boundaries and printing-induced structural defects. We present statistical analysis of geometric features that is enabled by the AI tool, showing strong spatial correlation of defects and the melt pool boundaries. The correlations of widths and heights of melt pools with dataset processing parameters show the highest sensitivity to thermal influences resulting from laser passes in adjacent and subsequent layer passes. The presented models and tools are demonstrated on the aluminum alloy and datasets produced with different sets of processing parameters. However, they have universal quality and could easily be adapted to different material compositions. The method can be easily generalized to microstructural characterizations other than optical microscopy.

additive manufacturing↗