Engineering topics
Publications and source records attributed to Flemings, M. C..
The paper is an overview of the status and science for the LODESTARS (Levitation Observation of Dendrite Evolution in Steel Ternary Alloy Rapid Solidification) research project. The program is aimed at understanding how melt convection influences phase selection and the evolution of rapid solidification microstructures.
The paper is an overview of the status and science for the LODESTARS research project. The program is aimed at understanding how melt convection influences phase selection and the evolution of rapid solidification microstructures
Containerless processing using electromagnetic levitation (EML) is a powerful technique in the investigation of reactive molten metal systems. On ground, the power required to overcome the weight of the sample is sufficient to cause significant heating and induce substantial melt convection. In microgravity, the heating and positioning fields may be decoupled and the field strength may be varied to achieve the desired level of convection within the limits set by the geometry of the levitation coil and the sample size. From high-speed digital images of the double recalescence behavior of Fe-Cr-Ni alloys in ground-based testing and in reduced-gravity aboard the NASA KC-135 parabolic aircraft, we have shown that phase selection can be predicted based on a growth competition model. An important parameter in this model is the delay time between primary nucleation and subsequent nucleation of the stable solid within the liquid/metastable solid array. This delay time is a strong function of composition and a weak function of the undercooling of the melt below the metastable liquidus. From the results obtained during the first Microgravity Sciences Laboratory (MSL-1) mission, we also know that convection may significantly influence the delay time, especially at low undercoolings. Currently, it is unclear what mechanism controls the formation of a heterogeneous site that allows nucleation of the austenitic phase on the pre-existing ferrite skeleton. By examining the behavior of the delay time under different convective conditions, we hypothesize that we can differentiate between several of these mechanisms to gain an understanding of how to control microstructural. evolution. We will anchor these predictions by examining samples quenched at different times following primary recalescence in microgravity. A second important parameter in the growth competition model is the identification of the growth rate of the stable phase into the semi-solid array that formed during primary recalescence. Current dendritic growth theory is inadequate in predicting solidification behavior under these conditions as metallographic analyses show that stable phase growth proceeds along the interface between the metastable solid and residual liquid. Since growth velocity is independent of the initial undercooling relative to the metastable liquidus, we hypothesize that purely thermal effects can be separated from other important growth model parameters by careful selection of the liquid composition in a ternary system.
The viscosity of a liquid metal was successfully measured for the first time by a containerless method, the oscillating drop technique. This method also provides a means to obtain a precise, non-contact measurement of the surface tension of the droplet. This technique involves exciting the surface of the molten sample and then measuring the resulting oscillations; the natural frequency of the oscillating sample is determined by its surface tension, and the damping of the oscillations by the viscosity. These measurements were performed in TEMPUS, a microgravity electromagnetic levitator (EML), on the Space Shuttle as a part of the First Microgravity Science Laboratory (MSL-1), which flew in April and July 1997 (STS-83 and STS-94). Some results of the surface tension and viscosity measurements are presented for Pd82Si18. Some observations of the fluid dynamic characteristics (dominant flow patterns, turbulent transition, cavitation, etc.) of levitated droplets are presented and discussed together with magnetohydrodynamic calculations, which were performed to justify these findings.
The rheology of SiC particulate/Al-6.5 pct Si composite slurries was explored. The rheological behavior of the composite slurries shows both thixotropic and pseudoplastic behaviors. Isostructural experiments on the composite slurries revealed a Newtonian behavior beyond a high shear rate limit. The rheology of fully molten composite slurries over the low to high shear rate range indicates the existence of a low shear rate Newtonian region, an intermediate pseudoplastic region and a high shear rate Newtonian region. The isostructural studies indicate that the viscosity of a composite slurry depends upon the shearing history of a given volume of material. An unexpected shear thinning was noted for SiC particulate + alpha slurries as compared to semi-solid metallic slurries at the same fraction solid. The implications of these findings for the processing of slurries into cast components is discussed.
A new casting process for fabrication of particle-reinforced metals is presented whereby a composite of particulate reinforcing phase in metal is first produced by pressure infiltration. This composite is then diluted in additional molten metal to obtain the desired reinforcement volume fraction and metal composition. This process produces a pore-free as-cast particulate metal-matrix composite. This process is demonstrated for fabrication of magnesium-matrix composites containing SiC reinforcements of average diameter 30, 10 and 3 microns. It is compared with the compocasting process, which was investigated as well for similar SiC particles in Mg-10 wt pct Al, and resulted in unacceptable levels of porosity in the as-cast composite.
The principal objectives of this overall investigation are to: study means for obtaining high undercooling in levitation melted droplets, and study structures produced upon the solidification of these undercooled specimens. Thermal measurements are made of the undercooling, and of the rapid recalescence, to develop an understanding of the solidification mechanism. Comparison of results is made with the modeling studies. Characterization and metallographic work is done to gain an understanding of the relationship between rapid solidification variables and the structures so produced. In ground based work to date, solidification of undercooled Ni-25 wt percent Sn alloy was observed by high-speed cinematography and the results compared with optical temperature measurements. Also in ground based work, high-speed optical temperature measurements were made of the solidification behavior of levitated metal samples within a transparent glass medium. Two undercooled Ni-Sn alloys were examined. Measurements were carried out on samples at undercoolings up to 330 K. Microstructures of samples produced in ground based work were determined by optical metallography and by SEM, and microsegregation by electron microprobe measurements. A series of flight tests were planned to conduct experiments similar to the ground based experiments. The Space Shuttle Columbia carried an alloy undercooled experiment in the STS 61-C mission in January 1986. A sample of Ni-32.5 wt percent Sn eutectic was melted and solidified under microgravity conditions.
The paper is concerned with structures and microsegregations in undercooled droplets of Ni-25 wt pct Sn and eutectic Ni-32.5 wt pct Sn alloys. An analysis of experimental results suggests that all samples solidify dendritically and that the final structures are largely the result of ripening. Experimental data on minimum solute composition in the samples produced are bounded by two curves both of which assume equilibrium at all liquid-solid interfaces during recalescence and subsequent cooling. The eutectic alloy samples often show a dendritic structure over the surface in areas where shrinkage is present. This structure appears to be the remnant of an original growth structure in which only limited ripening occurred, due to the rapid removal of interdendritic liquid by shrinkage.
A comparison is made between high speed cinematography and optical temperature measurements of the solidification of an undercooled Ni-25 wt pct Sn alloy. The first part of this study notes that solidification during the recalescence period at all undercoolings studied occurred in the form of a dendritelike front moving across the sample surface, and that the growth velocities observed agree with calculation results for the dendrite growth model of Lipton et al. (1986); it is concluded that the coarse structure observed comprises an array of much finer, solute-controlled dendrites. In the second part, attention is given to the solidification of levitated metal samples within a transparent glass medium for the cases of two undercooled Ni-Sn alloys, one of which is eutectic and another hypoeutectic. The data obtained suggest a solidification model involving dendrites of very fine structure growing into the melt at temperatures near the bulk undercooling temperature.
The Space Shuttle Columbia carried an Alloy Undercooling Experiment on its STS 61-C mission in January, 1986. The experiment was performed in an electromagnetic levitator. A sample of Ni-32.5 wt pct Sn eutectic was melted and solidified under microgravity conditions in the Space Shuttle. The specimen achieved only a fairly small undercooling, probably less than 30 K. The specimen was examined by optical and scanning electron microscopy. The surface and cross-sectional microstructures were primarily composed of normal lamellar eutectic, but showed several interesting features, including an apparent surface nucleation site, curved dendrites with nonorthogonal secondary arms, dendrite fragments with extremely fine arm spacing, submicron precipitates, and faceted crystals. The results of the space experiment are presented and compared with ground-based results obtained with the same alloy.
A comparison is made of microstructures of droplets of Ni-Sn alloys rapidly solidified by gas atomization and in a glass emulsifying medium. Cooling rate of the gas atomized particles ranged from 10 to the 3rd to 10 to the 6th K/s depending on droplet diameter (20-230 microns). In the hypoeutectic alloy studied, /Ni-(25 wt pct Sn)/, most particles showed a dendritic structure. These same particles, melted and resolidified in a glass medium using DTA (Differential Thermal Analysis), showed undercoolings up to 280 K: the structures were dendritic at low undercoolings and nondendritic at undercoolings above 220 K. It is concluded that the gas atomized particles exhibited little or no undercooling before nucleation; the solidification time of the undercooled emulsified droplets is substantially less than that of gas atomized droplets, and the undercooling required to achieve nondendritic structure depends on sample size.
The solidifying ingot interdendritic flow analysis in which channel segregates are assumed to be produced by interdendritic fluid flow dissolving channels in the primary dendrite network is presently refined by examining the flow through a dendrite network possessing a small defect. Attention is given to the section of the mushy zone in a solidifying casting. Since defects such as that presently treated are unavoidable in a real casting, a more reliable indication may be furnished of the occurrence of channel segregates.
Solidification of metal alloys with initial high undercoolings occurs with rapid recalescence due to rapid heat release of the latent heat of fusion. The recalescence temperature is usually higher than the solidus and/or the thermodynamic T sub o temperature of the alloy, depending on the initial undercooling and alloy composition. The rapid heating during recalescence alters the initially solidified structures, in ways that must include partial remelting, ripening, coarsening, and decomposition of the rapidly solidified primary metastable or supersaturated phases. New ways to study the solidification and remelting phenomena associated with the rapid heating during recalescence of undercooled alloys were developed. The phenomena are studied by using: (1) emulsions of iron and nickel base alloys in viscous liquid carriers; and (2) rapid heating of metal samples by electric discharge, using a technique similar to the exploding wire process (EWP), except with less power input. Experimental results are combined with theoretical analyses to better understand the solidification of levitated metal droplets with high undercooling, which relates to the solidification process.
A quantitative representation of the heat and fluid flow fields in electromagnetically levitated (positioned) metallic specimens is examined. Experimental studies as well as modelling of those studies on undercooling and solidification of levitated metal droplets are also considered. Thermal measurements will be made of the undercooling and solidification of levitated metal droplets. Thermal measurements will be made of the undercooling and of the details of the ultra-rapid recalescence. This levitation technique combined with quenching will be used to aid in the development of coherent model for the solidification process related to structural studies, including thermodynamics and kinetics for nucleation and metastable solute partition, kinetics for solid/liquid interface velocity with high undercooling, and heat flow consideration.
The present investigation attempts to provide an aid to the understanding of the essence of the gravitational influence on interdendritic flow. An analytic solution of the equations governing interdendritic fluid flow is presented for a simple case, involving a semiinfinite mushy zone whose isotherms are flat, parallel, and inclined at an angle to the force of gravity. It is found that gravity in ingots with narrow mushy zones mainly produces interdendritic flow parallel to the liquidus confined to the vicinity of the liquidus. This flow can be large in comparison to the usual shrinkage-induced flows. Its existence is caused by the rapid increase of permeability with fraction liquid near the liquidus. For this reason, it cannot appear in numerical calculations which ignore the rapid variation of permeability.
Experimental work on undercooling and structure of tin-lead droplets emulsified in oil is described. The droplets, predominantly in the size range of 10 to 20 microns, were cooled at rates (just before nucleation) ranging from about 0.1 to 1 million K/s. The higher cooling rates were obtained by a newly developed technique of quenching the emulsified droplets in a cold liquid. Measured undercoolings (at the lower cooling rates) ranged up to about 100 K. Structures obtained depend strongly on undercooling, cooling rate before and after nucleation, and alloy composition. Droplets containing up to 5 wt pct Pb were apparently single phase when undercooled and rapidly quenched. Droplets in the composition range of about 25-90 wt pct Pb solidified dendritically, even at the most rapid quench rates employed, apparently because these alloys undercooled only slightly before nucleation of the primary phase.
The present investigation is concerned with the subject of undercooling (i.e., supercooling) in the case of metal alloys, taking into account the effects of undercooling on microstructure and microsegregation in alloys which solidify in a crystalline manner. Techniques for obtaining a large degree of undercooling are discussed. These techniques make it possible to eliminate heterogeneous nucleants from the melt and to remove container nucleation effects. The nucleation behavior of small metal droplets is considered along with the formation of a dispersion of fine droplets in a suitable inert medium, the mixing of fine metal powders with glass powder, and the levitation melting technique. Attention is given to solidification with rapid interface velocity, aspects of dendritic morphology, and thermal measurements during solidification of undercooled droplets.
An electromagnetic furnace is being prepared for flights aboard the Space Shuttle. This apparatus is capable of melting metals and alloys up to 1400 C melting point by induction heating with subsequent solidification of the freely levitated melt without contact with any container. The solidification can be carried out with greatly reduced fields resulting in minimal heating and stirring of the free melt. Sequential specimens can be processed during flight. Several experiments are planned for a series of flights, beginning in 1985 with an undercooling experiment of NiSn alloys. These will be interspersed with detailed studies of fluid flow caused by low and high field levels in order to quantify the corresponding effect upon the solidification process.