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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Injector Design Tool Improvements: User's manual for FDNS V.4.5

The major emphasis of the current effort is in the development and validation of an efficient parallel machine computational model, based on the FDNS code, to analyze the fluid dynamics of a wide variety of liquid jet configurations for general liquid rocket engine injection system applications. This model includes physical models for droplet atomization, breakup/coalescence, evaporation, turbulence mixing and gas-phase combustion. Benchmark validation cases for liquid rocket engine chamber combustion conditions will be performed for model validation purpose. Test cases may include shear coaxial, swirl coaxial and impinging injection systems with combinations LOXIH2 or LOXISP-1 propellant injector elements used in rocket engine designs. As a final goal of this project, a well tested parallel CFD performance methodology together with a user's operation description in a final technical report will be reported at the end of the proposed research effort.

Chen, Yen-Sen↗
NASA NTRS1999

Real-Time Investigation of Solidification of Metal Matrix Composites

Casting of metal matrix composites can develop imperfections either as non- uniform distributions of the reinforcement phases or as outright defects such as porosity. The solidification process itself initiates these problems. To identify or rectify the problems, one must be able to detect and to study how they form. Until, recently this was only possible by experiments that employed transparent metal model organic materials with glass beads to simulate the reinforcing phases. Recent results obtained from a Space Shuttle experiment (using transparent materials) will be used to illustrate the fundamental physics that dictates the final distribution of agglomerates in a casting. We have further extended this real time investigation to aluminum alloys using X-ray microscopy. A variety of interface-particle interactions will be discussed and how they alter the final properties of the composite. A demonstration of how a solid-liquid interface is distorted by nearby voids or particles, particle pushing or engulfment by the interface, formations of wormholes, Aggregation of particles, and particle-induced segregation of alloying elements will be presented.

Kaukler, William↗
NASA NTRS1997

Real Time Characterization of Solid/Liquid Interfaces During Directional Solidification

A X-Ray Transmission Microscope (XTM) has been developed to observe in real time and in-situ solidification phenomenon at the solid/liquid interface. Recent improvements in the horizontal Bridgman furnace design provides real-time magnification (during solidification) up to 12OX. The increased magnification has enabled for the first time the XTM imaging of real-time growth of fibers and particles with diameters of 3-6 micrometers. Further, morphological transitions from planar to cellular interfaces have also been imaged. Results from recent XTM studies on Al-Bi monotectic system, Al-Au eutectic system and interaction of insoluble particles with s/I interfaces in composite materials will be presented. An important parameter during directional solidification of molten metal is the interfacial undercooling. This parameter controls the morphology and composition at the s/I interface. Conventional probes such as thermocouples, due to their large bead size, do not have sufficient resolution for measuring undercooling at the s/I interface. Further, the intrusive nature of the thermocouples also distorts the thermal field at the s/I interface. To overcome these inherent problems we have recently developed a compact furnace which utilizes a non-intrusive technique (Seebeck) to measure undercooling at the S/I interface. Recent interfacial undercooling measurements obtained for the Pb-Sn system will be presented. The Seebeck measurement furnace in the future will be integrated with the XTM to provide the most comprehensive tool for real time characterization of s/I interfaces during solidification.

Sen, S.↗
NASA NTRS1998

Real-Time X-Ray Microscopy of Al-Cu Eutectic Solidification

Recent improvements in the resolution of the X-ray Transmission Microscope (XTM) for Solidification Studies provide microstructure feature detectability down to 5 micrometers during solidification. This presentation will show the recent results from observations made in real-time of the solid-liquid interfacial morphologies of the Al-CuAI2 eutectic alloy. Lamellar dimensions and spacings, transitions of morphology caused by growth rate changes, and eutectic grain structures are open to measurements. A unique vantage point viewing the face of the interface isotherm is possible for the first time with the XTM due to its infinite depth of field. A video of the solid-liquid interfaces seen in-situ and in real-time will be shown.

Kaukler, William F.↗
NASA NTRS1998

Real-Time X-Ray Transmission Microscopy for Fundamental Studies Solidification

High resolution real-time X-ray Transmission Microscopy, XTM, has been applied to obtain information fundamental to solidification of optically opaque metallic systems. We have previously reported the measurement of solute profile in the liquid, phase growth, and detailed solid-liquid interfacial morphology of aluminum based alloys with exposure times less than 2 seconds. Recent advances in XTM furnace design have provided an increase in real-time magnification (during solidification) for the XTM from 4OX to 16OX. The increased magnification has enabled for the first time the XTM imaging of real-time growth of fibers and particles with diameters of 5 micrometers. We have applied this system to study of the kinetics of formation and morphological evolution of secondary fibers and particles in Al-Bi monotectic alloys to observe a previously unreported velocity dependent thermo-capillary depletion mechanism for Bi rich liquid which can penetrate many fiber diameters into the solid-liquid interface. In this talk we will discuss application of the XTM to the study the fundamentals of monotectic and eutectic solidification, the enhancement of XTM data with precise solid liquid interfacial temperature and thermal gradient measurement techniques, and the application of this technology to the study of the fundamentals of solidification in microgravity,

Curreri, Peter A.↗
NASA NTRS1999

A Real Time Investigation of Morphological Evolution During Solidification of Different Alloy Systems

Solidification phenomenon which occur at the solid/liquid (s/I) interface play a major role in the determination of structure and hence the technologically important properties of a casting. However, metals being opaque, conclusions related to several important phenomenon such as boundary layer thickness, morphological evolution, and eutectic and cell spacing are deduced from quenching experiments and subsequent post solidification metallographic analysis. Consequently, limited information is obtained about the dynamics of the process. This paper will discuss the recent efforts at the Space Science Laboratory, NASA Marshall Space Flight Center, to view and quantify in-situ and in real time the dynamics of the solidification process and to measure interfacial undercooling. First, a high resolution x-ray transmission microscope (XTM) has been developed to monitor fundamental interfacial phenomena during directional solidification of metals and alloys. The XTM operates in the range of 10-100 KeV and through projection is capable of achieving magnification of up to 16OX. Secondly, an innovative collapsible furnace has been designed to quantify interfacial undercooling by measuring the temperature of a moving s/I interface in reference to a fixed s/l interface. This measurement technique is non-intrusive in nature and is based on the Seebeck principle. In this paper real time results obtained to characterize the dynamics of irregular eutectic spacing will be presented. As an example fiber to lamella or plate transition in the Al-Al2Au eutectic system will be discussed. Further, a resolution limit of 25 micron has permitted viewing in real time morphological instability and cellular growth in Al-Au and Al-Ag systems. Simultaneously, a systematic investigation has been carried out to measure interfacial undercooling for Pb-1 wt.% Sn at and near the marginal stability regime. In conjunction with the XTM observations this study attempts to validate existing relationships between undercooling and growth velocity during plane front growth, marginal stability regime, and stable cellular growth.

Sen, S.↗
NASA NTRS1999

Gravitational Acceleration Effects on Macrosegregation: Experiment and Computational Modeling

Experiments were performed under terrestrial gravity (1g) and during parabolic flights (10-2 g) to study the solidification and macrosegregation patterns of Al-Cu alloys. Alloys having 2% and 5% Cu were solidified against a chill at two different cooling rates. Microscopic and Electron Microprobe characterization was used to produce microstructural and macrosegregation maps. In all cases positive segregation occurred next to the chill because shrinkage flow, as expected. This positive segregation was higher in the low-g samples, apparently because of the higher heat transfer coefficient. A 2-D computational model was used to explain the experimental results. The continuum formulation was employed to describe the macroscopic transports of mass, energy, and momentum, associated with the solidification phenomena, for a two-phase system. The model considers that liquid flow is driven by thermal and solutal buoyancy, and by solidification shrinkage. The solidification event was divided into two stages. In the first one, the liquid containing freely moving equiaxed grains was described through the relative viscosity concept. In the second stage, when a fixed dendritic network was formed after dendritic coherency, the mushy zone was treated as a porous medium. The macrosegregation maps and the cooling curves obtained during experiments were used for validation of the solidification and segregation model. The model can explain the solidification and macrosegregation patterns and the differences between low- and high-gravity results.

Leon-Torres, J.↗
NASA NTRS1998

Particle Engulfment and Pushing by Solidifying Interfaces LMS Mission Results

Results of the directional solidification experiments on Particle Engulfment and Pushing by Solidifying Interfaces (PEP) conducted on the space shuttle Columbia are reported. The experiment was manifested as part of The Life and Microgravity Science Mission. Two pure aluminum (99.999%) 9 mm cylindrical rods, loaded with about 2 vol.% 500 microns diameter zirconia particles were melted and directionally solidified in the microgravity (micro-g) environment of the shuttle. The particles were non-reactive with the matrices within the temperature range of interest. The experiments were conducted such as to insure a planar solid/liquid interface during solidification. Two different cartridge - crucible - sample designs were used: a spring-piston and expansion void. Both resulted in sound samples. Samples were evaluated post-flight for soundness by X-ray computer tomography (XCT).

Juretzko, Frank R.↗
NASA NTRS1998

Particle Engulfment and Pushing by Solidification Interfaces: Ground Experiments - Part 1

Directional solidification experiments have been carried out to determine the pushing/engulfment transition for two different metal/particle systems. The systems chosen were aluminum/zirconia particles and zinc/zirconia particles. Pure metals (99.999% Al and 99.95% Zn) and spherical particles (500 microns in diameter) were used. The particles were non-reactive with the matrices within the temperature range of interest. The experiments were conducted such as to insure a planar solid/liquid interface during solidification. Particle location before and after processing was evaluated by X-ray transmission microscopy for the Al/ZrO2 samples. All samples were characterized by optical metallography after processing. A clear methodology for the experiment evaluation was developed to unambiguously interpret the occurrence of the pushing/engulfment transition. It was found that the critical velocity for engulfment ranges from 1.9 to 2.4 micron/s for Al/ZrO2 and from 1.9 to 2.9 microns/s for Zn/ZrO2.

Juretzko, Frank R.↗
NASA NTRS1999

In-Situ Observations of Interaction Between Particulate Agglomerates and an Advancing Planar Solid/Liquid Interface: Microgravity Experiments

Results are reported of directional solidification experiments on particulate agglomerate pushing and engulfment by a planar solid/liquid (s/1) interface. These experiments were conducted on the Space Shuttle Columbia during the United States Microgravity Payload 4 (USMP-4) Mission. It was found that the pushing to engulfment transition velocity, V(sub ct),, for agglomerates depends not only on their effective size but also their orientation with respect to the s/l interface. The analytical model for predicting V(sub cr) of a single particle was subsequently enhanced to predict V(sub cr) of the agglomerates by considering their shape factor and orientation.

Sen, S.↗
NASA NTRS1998

Particle Engulfment and Pushing by Solidifying Interfaces: Micro-Gravity Experiments and Theoretical Analysis - Pt. 2

Results of the directional solidification experiments on Particle Engulfment and Pushing by Solidifying Interfaces (PEP) conducted on the space shuttle Columbia during the Life and Microgravity Science Mission are reported. Two pure aluminum (99.999%) 9 mm cylindrical rods, loaded with about 2 vol.% 500 micrometers diameter zirconia particles were melted and resolidified in the microgravity (microg) environment of the shuttle. One sample was processed at step-wise increased solidification velocity, while the other at step-wise decreased velocity. It was found that a pushing-to-engulfment transition (PET) occurred in the velocity range of 0.5 to 1 micrometers. This is smaller than the ground PET velocity of 1.9 to 2.4 micrometers. This demonstrates that natural convection increases the critical velocity. A previously proposed analytical model for PEP was further developed. A major effort to identify and produce data for the surface energy of various interfaces required for calculation was undertaken. The predicted critical velocity for PET was of 0.775 micrometers/s.

Stefanescu, Doru M.↗
NASA NTRS1998

Measurement of Interfacial Undercooling in a Dilute Pb-Sn Alloy Near the Regime of Morphological Instability

The solid/liquid (s/1) interfacial Seebeck technique was used to measure interfacial undercooling in a Pb-1 wt.% Sn alloy. For plane front solidification an undercooling in the range of 0.54-0.57C was recorded. However, for growth velocities between 6 to 15 micron/s the undercooling, increased with increase in velocity. 'Tbis is in contradiction to the theoretical predictions based on growth at the extremum condition. A modified analytical expression was developed based on the maro,,inal stability criterion to predict undercooling for growth velocities immediately over the limit of morphological stability. Between 6 to 15 microns/s the trend predicted by this modified expression is in qualitative agreement with the experimental results. This model is more consistent with the analysis of Venugopal and Kirkaldy which states that the extremum condition criterion is not applicable in the marginal stability regime. At higher growth velocities between 20 and 50 microns/s where stable cellular growth is expected the undercooling, decreased with increase in velocity. The predictions of Burden and Hunt based on extremum criterion agree reasonably well with the experimental results in this velocity range. Finally, the importance of non-equilibrium phase diagram parameters such as partition coefficient and liquidus slope were also evaluated using the experimental undercooling results obtained in this investigation.

Sen, S.↗
NASA NTRS1999

Interaction of Porosity with an Advancing Solid/Liquid Interface: a Real-Time Investigation

Problems associated with formation of porosity during solidification continue to have a daily impact on the metal forming industry. Several past investigations have dealt with the nucleation and growth aspects of porosity. However, investigations related to the interaction of porosity with that of a solidification front has been limited mostly to organic analogues. In this paper we report on real time experimental observations of such interactions in metal alloys. Using a state of the art X-Ray Transmission Microscope (XTM) we have been able to observe and record the dynamics of the interaction. This includes distortion of the solid/liquid interface near a poro.sity, solute segr,egation patterns surrounding a porosity and the change in shape of the porosity during interaction with an advancing solid/liquid interface. Results will be presented for different Al alloys and growth conditions. The experimental data will be compared to theory using a recently developed 2D numerical model. The model employs a finite difference approach where the solid/liquid interface is defined through the points at which the interface intersects the grid lines. The transport variables are calculated at these points and the motion of the solidification front is determined by the magnitude of the transport variables. The model accounts for the interplay of the thermal and solutal field and the influence of capilarity to predict the shape of the solid/liquid interface with time in the vicinity of porosity. One can further calculate the perturbation of the solutal field by the presence of porosity in the melt.

Sen, S.↗
NASA NTRS1999

Numerical Analysis of Temperature Gradients and Interface Shape During Directional Solidification of Al and Al-Cu Alloy Under Microgravity Conditions

Numerical modeling was undertaken to analyze the influence of radial thermal gradient on solid/liquid interface shape and convection patterns during solidification of pure Al and Al-4 wt. % Cu alloy. Steady state calculations were performed for different gravity levels and orientations. Furthermore, transient modeling was undertaken to investigate effect of the solidification velocity. The furnace configuration used in this analysis is the proposed International Space Station Furnace. Results from a thermal model of the furnace core were used as initial boundary conditions for solidification modeling. The Solidification model was adopted from previous work and was based on the finite element code FIDAP. Thermocouple data and quenched interface shape from a pure Al sample flown on the Life Sciences and Microgravity Spacelab (LMS) mission, July 1996 was used for model validation. Good agreement was obtained between the predicted interface shape and that measured from the quenched LMS sample. It was found that the imposed temperature boundary condition must be sufficiently smooth for the heat fluxes in the model to be self-consistent. The model predicted that alloy sample Al-Cu is more sensitive to variations in the gravity level compared to pure Al. For Al-Cu alloy, solute diffusivity is approximately 10(exp 4) times smaller than thermal diffusivity of pure Al. Hence, in a microgravity environment the weak convection has no measurable effect on the heat fluxes, but is still strong enough to affect concentration distribution. Since the alloy melting temperature is determined by concentration the interface shape depends on the level of convection. This was found not to be the case for pure metal.

Bune, Andris V.↗
NASA NTRS1999

Numerical Modeling and In-Situ Observations of the Dynamics of the Solid/Liquid Interface Morphology During Directional Solidification of Alloys

The departure from interface planarity and the subsequent evolution to a periodic array of cells or dendrites is a fundamental process that characterizes most microstructures in solidified alloys. The growing demand for high quality alloys and semiconductor crystals requires a precise methodology to predict and subsequently control both the interface morphology and the distribution of impurities, additives, and phases in the grown crystal. Apart from its practical significance, the study of morphological evolution has also been viewed as a means to unearth a general paradigm for pattern formation in nature. A previously developed 2D numerical model for the solid/liquid interface tracking has been further refined and used to simulate the time-evolution of the perturbations on the interface. The dynamics of the local growth velocity, interface undercooling and solute concentration at the interface has been theoretically predicted by means of the numerical model for Al-Cu and Pb-Sn alloys. The model shows that perturbations with a wavelengths, lambda greater than a critical wavelength lambda(sub c) continue to grow in time whereas perturbations with lambda < lambda(sub c) cease to propagate. The model further predicts that under certain conditions perturbation can also propagate along the interface. Comparison of these predictions with existing theories of pattern formation and experimental results will be discussed.

Catalina, Adrian V.↗
NASA NTRS2000

Numerical Calculation of the Drag Force Acting on an Insoluble Particle Moving in Front of a Solidifying Interface

The distribution of insoluble particles in a metal casting depends primarily on the interaction of the particles with the solid/liquid interface (SLI) during the solidification process. Whether a particle will be engulfed or continuously pushed by SLI is essentially determined by the balance of forces acting on the particle. An important component of this force balance is the drag force generated by the particle motion in front of the SLI. Previously developed mathematical models for particle/SLI interaction made use of steady-state solutions of this force provided by the lubrication theory. However, our numerical model based on the SLI tracking approach shows that not only the steady-state approach is inappropriate to model the interaction process but also that even at steady-state the theoretical solution underestimates the drag force. A regression analysis of steady-state numerical solutions for cylindrical particles moving normal to a flat SLI gave a relationship of the form F(sub d) (exp num) = (square root of 3) pi eta V(sub p)((R(sub p) / d) (exp 10 gamma/3)) as compared to the theoretical solution F(sub d) (exp theor) = 3 X (square root of 2) pi eta V(sub p)((R(sub p) / d) (exp 3/2)) where F(sub d) is the drag force, eta is the dynamic viscosity of the fluid, V(sub p) is the particle velocity, R(sub p) is the particle radius, gamma is Euler's constant (gamma is approximately equal to 0.577), and d is the width of the gap between the particle and the SLI. Model validation as well as the influence of the interface shape on the value of F(sub d) will also be discussed.

Catalina, Adrian V.↗
NASA NTRS1999

Numerical Analysis of Temperature Gradients and Interface Shape During Directional Solidification of Al and Al-Cu Alloy Under Microgravity Conditions

Numerical modeling was undertaken to analyze the influence of radial thermal gradient on solid/liquid (s/1) interface shape and convection patterns during solidification of pure Al and Al-4 wt% Cu alloy. The objective of the numerical task was to predict the influence of convective velocity on an insoluble particle near a s/l interface. These predictions would then be used to define the minimum gravity level (g) required to investigate the fundamental physics of interaction between a particle and a s/I interface. To satisfy this objective, steady state calculations were performed for different gravity levels and orientations with the gravity vector. ne furnace configuration used in this analysis is the proposed International Space Station Furnace, Quench Module Insert (QMI) 1. Results from a thermal model of the furnace core were used as initial boundary conditions for solidification modeling. General model of binary alloy solidification was based on the finite element code FIDAP. It was found that for the worst case orientation of 90 degrees with the gravity vector and a g level of 10(exp -4)g(sub o) (g(sub o) = 9.8 m/s(exp 2)) the dominant forces acting on the particle would be the fundamental drag and interfacial forces.

Bune, Andris V.↗
NASA NTRS1999

Particle Engulfment and Pushing by Solidifying Interfaces: USMP-4 One Year Report

The experiment Particle Pushing and Engulfment by Solidifying Interfaces (PEP) was conducted during the USMP-4 (United States Microgravity Payload-4) mission on board the shuttle Columbia in November 1997. This experiment has its place within the framework of a long-term scientific effort to understand the physics of particle pushing. The first flight experiment of this kind was performed with a metal matrix composite on board STS-78 in the summer of 1996. The use of opaque matrices limits the evaluation to pre-and post-flight comparison of particle locations within the sample. By using transparent matrices the interaction of one or multiple particles with an advancing solid/liquid (SL) interface can be studied in-situ. If this observation can then directly be transmitted from the orbiter to the scientists by video down-link, a real-time execution of the experiment is possible in a micro-gravity environment. Part of this experiment was an extensive training of the payload specialists to perform the experiment in orbit. This was further enhanced by the availability of video down-link and direct communication with the astronauts. Even though the PEP experiment is aimed at understanding the interaction of a liquid/solid interface with insoluble particles and thus is fundamental in scope, the prospective applications are not. Possible applications range from improved metal matrix composites to understanding and preventing frost heaving affecting roads.

Stefanescu, D. M.↗