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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Outlook on texture evolution in additively manufactured stainless steels: Prospects for hydrogen embrittlement resistance, overview of mechanical, and solidification behavior

Abstract Realizing application specific manufacture with fusion-based additive manufacturing (F-BAM) processes requires understanding of the physical phenomena that drive evolution of microstructural attributes, such as texture. Current approaches for understanding texture evolution in F-BAM are majorly considerate of the phenomena occurring only during solidification. This hinders the comprehensive understanding and control of texture during F-BAM. In this perspective article, we discuss several physical phenomena occurring during and after solidification that can determine texture in F-BAM processed stainless steels (SS). A crystal plasticity-coupled hydrogen adsorption-diffusion modeling framework is also leveraged to demonstrate the prospects of grain boundary engineering with F-BAM for enhanced hydrogen embrittlement resistance of SS. Implications of varying thermokinetics in F-BAM for solidification behavior of SS are discussed. Additionally, microstructural attributes that are key to high temperature mechanical performance of SS are highlighted. Considerations as outlined in this perspective article will enable grain boundary engineering and application specific microstructural design of SS with F-BAM. Graphical abstract

36 MATERIALS SCIENCE↗
DOE OSTI2024

Solidification of SRPPF Aqueous Recovery Liquid: Process Disruptions

Savannah River National Laboratory has identified a magnesium oxysulfate grout formulation to solidify the liquid effluent from the Savannah River Plutonium Processing Facility (SRPPF) Aqueous Recovery System (ARS). The formulation uses reactive, light burnt MgO, anhydrous MgSO 4 , and dead burnt MgO and provides good mixability, similar density to the original Portland Cement-based mix, and a leachate pH of 9.39, within the assumed Waste Isolation Pilot Plant (WIPP) brine pH range. The formulation will solidify the effluent using a solid first, lost paddle design, within a 55-gallon drum. A series of seven different process disruptions, or irregular processing during the expected ARS liquid effluent solidification process, were completed to assess the severity of the impact of the process disruption and how the formulation behaves under these conditions. Seven process disruptions were investigated including: No Mixing, Partial Mixing, Compacted/Stratified, Sealed, Overfilled, Underfilled, and Undermixed. The impact on solidification, leachate pH, Er (a Pu/Am surrogate) distribution, and density of the resulting grout were established. Overall, four of the process disruptions, No Mixing, Partial Mixing, Compacted/Stratified, and Overfilled, resulted in basic, unabsorbed liquid that would require additional solidification to be acceptable for WIPP. Most solids generated in this testing met the expected WIPP leachate pH requirements. Solids from the Compacted/Stratified process disruption test, however, produced a leachate pH slightly above the assumed range in the WIPP performance assessment. The distribution of Er for most of the tests was relatively consistent. The No Mixing process disruption test, however, resulted in non-homogeneous Er distribution, indicating that radioactive material would not be evenly distributed throughout this solid’s matrix. The Overfilled test is the only mix with a density slightly below the acceptable value. The Sealed and Overmixed tests produced a solid closest to the standard mix with no unabsorbed liquid, expected leachate pH levels, consistent Er concentrations, and expected density, indicating these process disruptions do not have a negative impact on the final grout form. Based on the other process disruptions, it is critical to have premixed dry materials and a well-defined mixing process to produce a solid, homogeneous magnesium oxysulfate cement, with no unabsorbed liquid. These process disruption tests show that the lack of adequate mixing is fundamental to creating an improperly solidified material that may require remediation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Geometry-Dependent Solidification Regimes in Metal Additive Manufacturing

Recent modeling and experimental work in additive manufacturing has suggested that cross-sectional geometry may play a significant role in the local development of the solidification structure through its influence on the heat source path. This effect has been rationalized as the transition from a quasi-static point heat source regime, to a regime dominated by the quasi-static motion of an equivalent line source. This work provides a simple analytical framework for determining the conditions under which a system transitions between these regimes. Here, a transient semi-analytical heat transfer model is used to examine a wide range of process conditions and material properties. A simple analytical expression is derived and shown to accurately predict the transition between solidification regimes over these conditions. The functional form of this expression is then used to help understand the importance of various material properties, process parameters, and geometric factors on the characteristics of the solidification conditions. This approach may be used as a simple guideline for optimizing process conditions in response to variations in cross-sectional geometry to produce more consistent microstructural distributions in additively manufactured components.

36 MATERIALS SCIENCE↗
NASA NTRS2023

Solidification Furnace for In Situ Observation of Bulk Transparent Systems and Image Analysis Methods

This paper aims to describe the experimental framework of the Directional Solidification Insert (DSI), installed onboard the International Space Station (ISS), dedicated to the in situ and real-time characterization of the dynamic selection of the solid-liquid interface morphology in bulk samples of transparent materials under diffusive growth conditions. The in situ observation of the solid-liquid interface is an invaluable tool for gaining knowledge on the time-evolution of the interface pattern because the initial morphological instability evolves nonlinearly and undergoes a reorganization process. The result of each experiment, characterized by the sample concentration, a thermal gradient and a pulling rate, is a large number of images. Interpretation of these images necessitates a robust identification of each cell/dendrite position and size during the entire solidification. Several image analysis methods have been developed to achieve this goal reliably despite varying contrast and noise levels, and are described in details. Typical solidification experiments are presented and the dynamics of the pattern formation are analyzed to illustrate the application of the image analysis methods.

Programming languages↗
NASA NTRS2025

Simulations of Large-Scale Zero Boiloff, Densification, and Solidification of Hydrogen

An Integrated Refrigeration and Storage (IRAS) experimental system called the Ground Operations and Demonstration Unit for Liquid Hydrogen (GODU-LH2) demonstrated the ability store cryogens in a zero boiloff (ZBO) process, and to densify liquid hydrogen by reducing the temperature and pressure down to the triple point resulting in solidification. The incompressible Navier-Stokes was utilized to simulate ZBO, densification, and solidification of liquid hydrogen (LH2) in the IRAS tank. The simulations were performed using a commercially available Computational Fluid Dynamics (CFD) pressure-based mass and momentum flow model and an enthalpy-porosity energy model. Results demonstrated the simulation’s ability to predict time-dependent flow and temperature fields and solid-liquid phase locations for hydrogen during ZBO, densification, and solidification. The simulations showed good agreement with experimental data, with errors within acceptable ranges for temperature and pressure predictions, provided detailed insights into natural convection and solid-liquid phase change dynamics. These findings are critical for the design of future cryogenic fluid management systems.

Computational Fluid Dynamics↗
DOE OSTI2025

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

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

additive manufacturing↗
DOE OSTI2023

Minor Elements and Solidification Cracking During Laser Powder-Bed Fusion of a High $\gamma ^{\prime }$ CoNi-Base Superalloy

Here, the cracking behavior of a high γ' volume fraction CoNi-base superalloy fabricated via laser powder bed fusion (LPBF) is studied in relation to the content of carbon and boron. Severe cracking occurred with the increase in boron content from 0.08 to 0.16 at. pct (0.015 to 0.029 wt pct), while compositions with 0.1 to 0.36 at. pct C (0.02 to 0.076 wt pct) and 0.08 at. pct B exhibited minimal cracking. Assessment of cracks in the high-boron composition shows a variation in crack density with printing parameters, and alignment of the cracks with the build direction. Scanning electron microscopy (SEM) of the crack surfaces shows evidence of a solidification cracking mode. Differential thermal analysis (DTA) reveals a decreased incipient melting temperature for the high-boron composition, and atom probe tomography (APT) is used to measure the enrichment at grain boundaries, revealing distinct boron segregation. Scheil-Gulliver solidification simulations for the different C and B levels are consistent with the incipient melting behavior observed with DTA. Evaluation of the solidification cracking susceptibility from the simulations allow for comparison of the CoNi alloy behavior to Ni-base superalloys studied for LPBF fabrication and displays how such metrics may aid in the design of new precipitation-strengthened superalloys for additive manufacturing (AM).

36 MATERIALS SCIENCE↗
DOE OSTI2019

Multiscale dendritic needle network model of alloy solidification with fluid flow

We present a mathematical formulation of a multiscale model for solidification with convective flow in the liquid phase. The model is an extension of the dendritic needle network approach for crystal growth in a binary alloy. We propose a simple numerical implementation based on finite differences and step-wise approximations of parabolic dendritic branches of arbitrary orientation. Results of the two-dimensional model are verified against reference benchmark solutions for steady, unsteady, and buoyant flow, as well as steady-state dendritic growth in the diffusive regime. Simulations of equiaxed growth under forced flow yield dendrite tip velocities within 10% of quantitative phase-field results from the literature. Finally, we perform illustrative simulations of polycrystalline solidification using physical parameters for an aluminum-10wt% copper alloy. Resulting microstructures show notable differences when taking into account natural buoyancy in comparison to a purely diffusive transport regime. The resulting model opens new avenues for computationally and quantitatively investigating the influence of fluid flow and gravity-induced buoyancy upon the selection of dendritic microstructures. Further ongoing developments include an equivalent formulation for directional solidification conditions and the implementation of the model in three dimensions, which is critical for quantitative comparison to experimental measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Sensitivity of cellular automata grain structure predictions for high solidification rates

Understanding as-solidified grain structure development during constrained (G 0) alloy solidification conditions is a necessary component of understanding the larger process-microstructure relationships during additive manufacturing (AM) processing. This study applies a cellular automata (CA) model, for static solidification velocities and thermal gradients on the order of those expected in AM melt pools, to investigate grain shape development across ranges of input parameters governing temperature field evolution, nucleation, and growth. Variation in nucleated grain shape from columnar to equiaxed as a function of thermal gradient and nucleation density is modeled with CA and verified against the established transition model of Hunt and Gaumann. Furthermore, while thermal conditions and nucleation density are shown to have the largest roles on microstructure development, the sensitivity of grain structure was very unevenly distributed across parameter space. In particular, it was found that microstructure is very sensitive to mean nucleation undercooling and the interfacial response function in process space regimes near grain structure transitions, but entirely controlled by a combination of thermal gradient, solidification velocity, and nucleation density away from such transitions. The understanding of grain shape sensitivity obtained through CA modeling, particularly at large thermal gradient and nucleation density, will be necessary for accurate microstructure prediction during the extreme processing conditions and large input parameter uncertainty common to AM.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The timing of lunar solidification and mantle overturn recorded in ferroan anorthosite 62237

Ferroan anorthosite suite (FAS) rocks are widely interpreted to represent primordial lunar crust. Despite their importance in pinpointing the timing of lunar crust formation, robust chronological investigations for this rock type are scarce. Here, we report the Ar-Ar, Rb-Sr, and Sm-Nd isotopic systematics for the FAS troctolitic anorthosite 62237. The Ar-Ar isotopic system has been reset by a thermal event at 3710 ± 48 Ma, and the Rb-Sr isotopic systematics has been disturbed such that a Rb-Sr isochron age cannot be determined. However, an internal isochron for the Sm-Nd isotopic system has yielded an age of 4350 ± 73 Ma (MSWD = 2.0) with an initial ε 143 Nd CHUR of -0.53 ± 0.26. The mineral and whole-rock fractions of 62237 plot on the same internal isochron as FAS sample 60025. The combined datasets define an age of 4372 ± 35 Ma (MSWD = 4.0) with an initial ε 143 Nd CHUR of -0.17 ± 0.22. Literature Sm-Nd data for FAS and Mg-suite whole-rocks also plot on the 60025-62237 isochron. The coherence of data from both FAS and Mg-suite rocks examined thus far suggests that both rock suites formed contemporaneously from identical, or nearly identical, sources. In addition, the concordance of FAS and Mg-suite ages suggests that primordial crust solidification either involved both magmatic suites, or that Mg-suite magmatism was contemporaneous with FAS magmatism within resolution of the Sm-Nd chronometer. The ages for FAS and Mg-suite also coincide with the formation ages of the mare basalt source regions and urKREEP. Ferroan anorthosite suite rocks and urKREEP are thought to represent primordial LMO solidification products, whereas Mg-suite and the mare basalt source regions are argued to represent mixtures of various LMO crystallization products that were formed during density-driven overturn of the LMO. The concordance of ages implies that the 4372 ± 35 Ma Sm-Nd isochron records the age of mantle overturn, and that overturn occurred during, or shortly after, solidification of the LMO.

58 GEOSCIENCES↗
DOE OSTI2026

Enhancing microsegregation during rapid directional solidification through ternary microalloying

The nano-cellular dendritic microstructure formed during rapid directional solidification in powder bed fusion additive manufacturing creates unique properties such as simultaneous improvement in strength and ductility. However, process control of microsegregation features remains challenging due to low sensitivity of critical solidification mechanisms to process parameters. This study leverages microalloying to achieve large changes in dendrite composition, microstructure, and interdendritic zone width during laser powder bed fusion without modifying process parameters. CALPHAD simulations predict that the addition of Zr significantly steepens the solidus line of the dilute Cu-Cr alloy system, leading to enhanced Cr rejection into the melt and greater than 95% reduction in solubility of Cr in the solidified Cu matrix. Experimental validation using time-of-flight secondary ion mass spectrometry and Kelvin probe force microscopy reveals that the ternary alloy containing 0.01 wt% Zr exhibited wider interdendritic regions compared to the binary, a significantly higher number of Cr-rich particles within interdendritic regions, near-complete ejection of oxygen impurities from the matrix, and greater nanoscale work function contrast. These features indicate more aggressive Cr segregation in the presence of Zr and a purer Cu matrix and provide a potentially robust method for engineering the nano-cellular dendritic solidification microstructure.

CALPHAD↗
DOE OSTI2023

Cell invasion during competitive growth of polycrystalline solidification patterns

Abstract Spatially extended cellular and dendritic array structures forming during solidification processes such as casting, welding, or additive manufacturing are generally polycrystalline. Both the array structure within each grain and the larger scale grain structure determine the performance of many structural alloys. How those two structures coevolve during solidification remains poorly understood. By in situ observations of microgravity alloy solidification experiments onboard the International Space Station, we have discovered that individual cells from one grain can unexpectedly invade a nearby grain of different misorientation, either as a solitary cell or as rows of cells. This invasion process causes grains to interpenetrate each other and hence grain boundaries to adopt highly convoluted shapes. Those observations are reproduced by phase-field simulations further demonstrating that invasion occurs for a wide range of misorientations. Those results fundamentally change the traditional conceptualization of grains as distinct regions embedded in three-dimensional space.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Analytical model for balling defects in laser melting using rivulet theory and solidification

In laser welding and additive manufacturing communities, the balling (humping) defect is primarily attributed to the Plateau–Rayleigh fluid instability (PRI) with a few authors suggesting fluid jetting and volume conservation as alternative mechanisms. As analytical descriptions of these mechanisms are unavailable, combining them into a single formalism is unfeasible. We present a new model of PRI with higher accuracy, accounting for competition with solidification, to compare the expected behavior with known experimental trends when fluid jetting is neglected. We adapt a rivulet instability model from fluid physics to account for the stabilizing effects of the substrate, which the traditional cylindrical-jet geometry does not account for and estimate the instability growth rate. Our model yields a continuous transition from non-balling to balling hitherto lacking in current literature and predicts instability growth at higher wavelengths with strong sensitivity to the solidification front curvature. While the fluid surface is most unstable for shallow melt pools, the absolute magnitude of balling relevant to printing defects scales with melt pool depth and has a maximum for a given melt pool geometry. Synchrotron-based x-ray radiography of thin samples indicates that PRI growth rates and solidification can be comparable in magnitude and thus compete, as we find in this work. We predict that deviations between model predictions and our experimental results demonstrate the importance of fluid flows and heat transport in the balling process. Our experiments further demonstrate at least one mechanism by which the melt pool length and the balling wavelength are not equivalent, as commonly claimed.

Taylor, Z. [Stanford Univ., CA (United States); SL↗
DOE OSTI2020

Compression-induced solidification of shock-melted cerium

Compression induced solidification has been observed in cerium on nanosecond timescales. For this study, a series of experiments were conducted on Sandia National Laboratories' Z Facility in which cerium was shock melted and subsequently shocklessly, or ramp, loaded across the melt line inducing solidification. The signature of solidification manifested in the recovery of material strength and the propagation of waves at the local elastic sound velocity. Density functional theory simulations of cerium along the experimental phase-space path exhibit spontaneous freezing to a tetragonal phase at the same pressure and closely predict the observed physical properties of solid and liquid cerium near melt.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1972

Thermal modeling of phase change solidification in thermal control devices including natural convection effects

Natural convection effects in phase change thermal control devices were studied. A mathematical model was developed to evaluate natural convection effects in a phase change test cell undergoing solidification. Although natural convection effects are minimized in flight spacecraft, all phase change devices are ground tested. The mathematical approach to the problem was to first develop a transient two-dimensional conduction heat transfer model for the solidification of a normal paraffin of finite geometry. Next, a transient two-dimensional model was developed for the solidification of the same paraffin by a combined conduction-natural-convection heat transfer model. Throughout the study, n-hexadecane (n-C16H34) was used as the phase-change material in both the theoretical and the experimental work. The models were based on the transient two-dimensional finite difference solutions of the energy, continuity, and momentum equations.

Ukanwa, A. O.↗
NASA NTRS1974

Eutectic solidification

The possibilities of using the low-gravity space environment for the processing of directionally solidified materials in order to remove the limitations imposed by the L-g earth environment have led to a careful evaluation of the directional solidification process and the results commonly obtained. Defects in the regularity of the microstructure have been identified as one of the most important areas where present processing technology needs to be improved. One-g environment material processing must also be carefully characterized before it can be determined if zero-g processing will produce significant benefits in eutectic and off-eutectic solidification. It is suggested that a combination of experimental and analytical thermal studies will be required to optimize the solidification process in order to minimize the structural defects which occur due to present processing techniques.

Douglas, F. C.↗
NASA NTRS1973

Investigation of solidification in zero-gravity environment: M553 sphere forming experiment. Nickel-silver alloy evaluation

The processing of nickel-silver alloy specimens in space is discussed. Four specimens were melted only partially, while a fifth was melted completely and assumed after solidification a perfectly spherical shape. Growth of the solid was epitaxial on the unmelted material or on the retaining sting and occurred without undercooling. Solidification was dendritic in all cases with nonequilibrium silver particles forming monotectically between dendrite arms. Substantial loss of silver by evaporation took place. Evaporation of the silver within internal gas cavities on the melt was followed by surface condensation after completion of solidification and cooling, leading to a silver-rich lining in these cavities. The material gave no microstructural evidence of any reduction in liquid convection.

Kattamis, T. Z.↗
NASA NTRS1975

External field effects on diffusion and solidification derived from the free-volume model

Expressions for the diffusion coefficient and the solidification rate from the free-volume model of liquids developed by Turnbull and Cohen have been used to estimate the effects which microgravity and magnetic fields will have on these quantities. The mathematical formalism describing changes of the diffusion coefficient and the solidification rate is the same for both the microgravity and magnetic field cases, but the difference between the magnitudes of the two effects is quite large. The change in the two parameters is found to be less than .0001% for the microgravity case and on the order of 0.1 to 1.1% for the magnetic field case for four representative materials. The diffusion coefficient and the solidification rate are found to increase under the influence of an applied magnetic field, and this is in agreement with experimental observations.

Miller, R. I.↗