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Results for “Directional solidification”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

On the formation mechanism of the ring-like microstructure of high-pressure die-cast A390 alloy

Highlights: • High-pressure die casting A390 alloy exhibited ring-like microstructure consisted of PSPs-free and PSPs-rich zones. • With 3D data, the size and morphology distribution of PSPs showed similar tendency regardless of the location. • The latent heat released from the PSPs led to the formation of ring-like band. • Widely observed defect band was inhibited because of the precipitation and growth of PSPs during solidification. - Abstract: The microstructure of the A390 alloy during high pressure die casting (HPDC), including pores, primary silicon particles (PSPs) and Cu-rich phases was characterized using synchrotron X-ray tomography. On the cross section of the sample exhibited ring-like or band microstructure, which comprised multiple PSPs-free and PSPs-rich zones. The PSPs distributed evenly in both size and morphology regardless of the ring-like microstructure. The size of aluminum dendrites changed according to the location of the ring-like microstructure, and was highly dependent on the local latent heat released from the PSPs as well as the distribution of the ‘net’ Cu-rich phases. Along the radial direction of the sample exhibited an abrupt increase of pores, indicating a tendency for forming a defect band in but such tendency was inhibited because of the huge amount of latent heat released by the PSPs during solidification, which was quite different from that of either magnesium alloys or hypoeutectic aluminum alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Localized orientation gradients in additively manufactured stainless steel 316H structures

The high solidification rates during additive manufacturing cause highly localized thermal and strain gradients. The effect of these gradients on the evolution of local orientation misorientations within a grain is not well understood. In this study, stainless steel 316H parts were fabricated via laser powder bed fusion using three different energy densities: 43, 71, and 135 J/mm 3 . Electron backscatter diffraction showed that the maximum misorientations of the grains can be up to 25° along the build direction. Misorientation gradients (RM g ) within grains are process-dependent and can change from 0.036°/μm to 0.015°/μm with increased volumetric energy densities. In conclusion, the characterized misorientation gradients are an indication of the level of dislocations and, to an extent, the plastic deformation resulting from the rapid solidification during laser powder bed fusion.

316H↗
DOE OSTI2023

Transmission electron microscopy of the rapid solidification microstructure evolution and solidification interface velocity determination in hypereutectic Al-20at.%Cu after laser melting

The evolution of rapid solidification (RS) microstructure and solidification interface velocity has been studied experimentally by in-situ transmission electron microscopy and postmortem characterization for hypereutectic Al-20at.%Cu (37 wt.%Cu) after laser melting. Four morphologically distinct regions formed via growth modes changing from θ-Al 2 Cu phase dendrites to eutectic cell growth, possibly α-Al dendrite growth (α-cell), banded growth, and α-Al plane front growth. Tendency for faceting and low capacity for solute trapping limited the θ-phase dendrite growth to solidification interface velocity v < 0.07 m/s. Consequently, formation of pro-eutectic micro-constituent was suppressed, and RS microstructure formation was dominated by eutectic, α-cell, and banded morphology grains for the Al-20at.%Cu alloy. Eutectic growth operated for interface velocity of 0.1 m/s ≤ v < 0.3 m/s, with a transition from regular lamellar, 2-λ and 1-λ mode to a dense irregular morphology dominated by α-phase at v = 0.3 m/s. Interface temperature calculations indicated feasibility of α-cell growth mode for 0.3 m/s ≤ v < 0.7 m/s. Banded growth occurred for 0.7 m/s ≤ v < 1.3 m/s. Plane front α-phase growth was evident for interface velocities v ≥ 1.3 m/s. Previous work on rapid solidification microstructure development in hypereutectic Al-Cu alloys reported a regime of α-cell growth subsequently to eutectic and prior to transition to banded growth for Al-19at.%Cu (36 wt.%Cu), while for Al-22at.%Cu (40 wt.%Cu) eutectic growth transitioned directly to α-plane front growth without emergence of a banded regime. Finally, based on the current study the disappearance of the banded growth regime occurs for a composition larger than 20at.%Cu.

36 MATERIALS SCIENCE↗
DOE OSTI2023

3D Printed eutectic aluminum alloy has facility for site-specific properties

Additive manufacturing (AM) has the ability to print structures with site-specific properties. Existing AM approaches for site-specific properties are, however, based on complex processing-microstructure relationships in conventional alloys that were not designed for this purpose. Here, in this work, we report a straightforward approach for achieving site-specific properties that takes advantage of eutectic solidification characteristics. We demonstrate that the yield strength of a eutectic Al-Cu-Ce-Zr alloy can be tuned by varying the laser scan speed in concert with hatch spacing in laser powder bed fusion AM. A faster speed increases solidification rate resulting in finer eutectic spacing and higher strength. The hatch spacing is reduced at faster speeds to ensure overlap between melt pools which become smaller with increasing scan speed. The yield strength and its anisotropy relative to build direction are further tunable with a heat treatment. The scan speed-eutectic spacing-strength relationship is successfully applied to print a complex pattern of site-specific hardness in the alloy. The generalized principle of using AM for a eutectic alloy to create site-specific properties and anisotropy in properties is demonstrated.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Note: Strain sensitivity comparison between fiber Bragg gratings inscribed on 125 and 80 micron cladding diameter fibers, case study on the solidification monitoring of a photo-curable resin

The influence of fiber Bragg grating diameter when measuring strain is investigated and quantified. Two fiber Bragg gratings with bare cladding diameter of 125 μm and 80 μm are produced by excimer laser irradiation through a phase mask, and are used to simultaneously monitor the Bragg wavelength shift due to the strain produced by the solidification of a photo-curable resin during light exposure. It is found that the ratio of the measured strains in the two fiber Bragg gratings is close to the inverse ratio of the fiber’s cladding diameter. These results represent a direct simultaneous comparison between 125 μm and 80 μm diameter fiber Bragg grating strain sensors, and demonstrate the feasibility of strain measurements in photo-curable resins using bare 80 μm cladding diameter fiber Bragg gratings with an increased sensitivity and spatial resolution compared with standard 125 μm diameter fiber Bragg gratings.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Characterization of texture and grain boundary character distributions of selective laser melted Inconel 625 alloy

Highlights: • <110> texture along layer build direction was generated in as-SLMed Inconel 625. • The stress relief process dominates texture and GBCD evolution. • SLMed IN 625 alloy can be GBEed via suitable post annealing. - Abstract: Select laser melting (SLM) is one of the practical metal additive manufacturing processes to fabricate complex structures. The inhomogeneous microstructure and high residual stress are typically resulted from a non-uniform melting and rapid solidification during a SLM process, which has the significant impact on part dimensional instability, corrosion resistance, and mechanical properties. The bulk of current research is limited to the general characterization of grain size, texture, and mechanical properties. However, grain boundary character distribution (GBCD) and its relationship with texture are yet to be understood. This study has shown that the preferred <110> along building direction and <100> along laser scanning direction were produced. The high density of low angle grain boundary (LAGB) can be an indicator of residual stress levels in the as-SLMed samples. The newly-developed ∑3, ∑9 and ∑27 grain boundaries were heavily populated, and the cluster of grains interfaced by ∑3{sup n} (n = 0, 1, 2…) was introduced at the expense of LAGB only at high recrystallization annealing (1150°C or over). The research results suggest that GBCD optimization be possible in the SLMed Inconel 625 alloy via suitable post annealing, which allows improving intergranular corrosion resistance and enhancing mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Resistivity distribution and donor properties of antimony-doped n -type Czochralski silicon ingots

We investigate antimony (Sb)-doped Czochralski-grown silicon as an alternative n-type substrate for photovoltaic applications, and characterize their axial resistivity distribution, donor properties, and mechanical strength. We find that Sb-doped ingots can achieve a more uniform resistivity distribution along the axial direction compared to P-doped counterparts. Dopant concentration profiles in P-doped ingots can be accurately modelled using the standard Scheil's equation, accounting only for dopant segregation during solidification. In contrast, modelling Sb-doped ingots requires consideration of both dopant segregation and evaporation effects to fit the dopant distribution accurately. Using electron paramagnetic resonance spectroscopy at 9 K, we observe two hyperfine lines in P-doped samples, and six hyperfine lines for Sb 121 and eight for Sb 123 isotopes, with the number of hyperfine lines governed by the nuclear spins. We further identify two-atom Sb clustering in the Sb-doped wafers, confirmed through simulations of the additional weak electron paramagnetic resonance peaks. Finally, we find that 140 μm as-cut planar Sb-doped wafers exhibit slightly higher mechanical strength compared to P-doped wafers.

14 SOLAR ENERGY↗
DOE OSTI2018

Experimental Investigations on Solidification of 500-kg Steel Ingots with Laboratory Trials

The present work focuses on the solidification process of large steel ingots. Several complex solidification phenomena in large ingots were investigated by means of experimental hot modeling and cold modeling. In hot modeling, a 500 kg ingot solidified slowly in a specially insulated mold and this slow solidification process simulates the solidification of industrial scale ingots with a weight between 3 and 6 t. Temperature was measured by thermocouples during solidification and curves were plotted, and as-cast structure and macrosegregation of alloying elements were quantified. The A segregates were produced in the laboratory hot trials and quantitatively investigated. Meanwhile, water modeling (cold modeling) using NH{sub 4}Cl solution was conducted with different cooling/heating conditions. Macroscopic crystal growth phenomena, such as dendritic growth, sedimentation of crystals, and convective fluid flow, were directly observed and analyzed, and flow channels were also observed and compared with A segregates in the hot modeling.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Numerical Simulation of Solidification of Colloids Inside a Differentially Heated Cavity

Development of the solid–liquid interface, distribution of the particle concentration field, as well as the development of thermosolutal convection during solidification of colloidal suspensions in a differentially heated cavity are investigated. The numerical model is based on the one-fluid mixture approach combined with the single-domain enthalpy porosity model for phase change, and it is implemented in FLUENT software package. The linear dependence of the liquidus and solidus temperatures with the concentration of the nanoparticles was assumed. A colloidal suspension consisting of water and copper or alumina nanoparticles were considered. In the current investigation, the nanoparticle size selected was 5 and 2 nm. The suspension was solidified unidirectionally inside a square differentially heated cavity that was cooled from the left side. It was found that the solid–liquid interface changed its morphology from a planar shape to a dendritic one as the solidification process proceeds in time, due to the constitutional supercooling that resulted from the increased concentration of particles at the solid–liquid interface rejected from the crystalline phase. Initially, the flow consisted of two vortices rotating in opposite directions. However, at later times, only one counter clockwise rotating cell survived. Changing the material of the particle to alumina resulted in crystallized phase with a higher concentration of particles. If it is compared to that of the solid phase resulted from freezing the copper–water colloidal suspension. Furthermore, decreasing the segregation coefficient destabilizes the solid–liquid interface and increases the intensity of the convection cell with respect to that of the case of no particle rejection. At slow freezing rates, the resulting crystal phase consisted of lower particle content compared to the case of higher freezing rate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Quantifying Equiaxed vs Epitaxial Solidification in Laser Melting of CMSX-4 Single Crystal Superalloy

The competition between epitaxial vs. equiaxed solidification has been investigated in CMSX-4 single crystal superalloy during laser melting as practiced in additive manufacturing. Single-track laser scans were performed on a powder-free surface of directionally solidified CMSX-4 alloy with several combinations of laser power and scanning velocity. Electron backscattered diffraction (EBSD) mapping facilitated identification of new orientations, i.e., “stray grains” that nucleated within the fusion zone along with their area fraction and spatial distribution. Using high-fidelity computational fluid dynamics simulations, both the temperature and fluid velocity fields within the melt pool were estimated. This information was combined with a nucleation model to determine locations where nucleation has the highest probability to occur in melt pools. In conformance with general experience in metals additive manufacturing, the as-solidified microstructure of the laser-melted tracks is dominated by epitaxial grain growth; nevertheless, stray grains were evident in elongated melt pools. It was found that, though a higher laser scanning velocity and lower power are generally helpful in the reduction of stray grains, the combination of a stable keyhole and minimal fluid velocity further mitigates stray grains in laser single tracks.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Evaluation of the Microstructure and Performance of Fe-21Cr-15Ni-6Mn-Nb Nonmagnetic Stainless Steel Welded Joints

In the present study, double-sided gas shield welding (GSW), in a single pass, was applied to Fe-21Cr-15Ni-6Mn-Nb nonmagnetic stainless steel plate. The microstructure and performance of the welded joint were investigated via microstructural and phase analysis, mechanical testing and magnetic analysis. The results showed a satisfactory micrographic appearance with full penetration, and no solidification defects observed in the welded joint, which showed typical epitaxial growth characteristics in the welding solidification. Slight grain growth, with an average size of ~ 18.9 μm, occurred in the heat-affected zone (HAZ). The primary dendrite arms, on both sides of welding joint, grew along the direction of the temperature gradient and met at the centerline of the weld with no parting microstructure in evidence. The secondary dendrite arm spacing was stable in all parts of the weld zone (WZ). The hardness of the weld zone was higher than that of the HAZ and the base metal (BM), with the lowest hardness occurring in the HAZ. The results of tensile testing showed a higher strength of the welded metal (WM) compared to the BM, and a good strength-ductility balance of the welded joint. The impact energy of the HAZ was higher than that of the WZ, corresponding to 60.5 J at room temperature and 52.7 J at − 196 °C. Microvoid coalescence, concurrent with crack propagation along the direction of the long axis of the dendritic sub-grains, was observed during plastic deformation in the WZ. Additionally, the excellent paramagnetic characteristics of the welded specimens were revealed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Thermal Conductivity of AM Fabricated Stainless Steel 316L Part

Thermal properties are an integral part of many diverse engineering applications, and additive manufacturing (AM), particularly laser powder bed fusion (LPBF) is shown to affect thermal properties due to the laser processing parameters. For 316L stainless steel, there is little prior research to determine the effects of the process on thermal properties. In this work, the temperature gradient is shown to create uniform, chess board-like distributions of grains in the build direction. These zones create dislocations which were visualized with EBSD techniques. Processing parameters cause hierarchal grain size distribution, with localized concentrations of small grains and large grains. Thermomechanical stresses in the rapid solidification increases dislocation density during grain formation. Previous research shows a higher density of dislocations decreases local thermal conductivity. Local and bulk thermal conductivity are shown in this work to have statistically lowered values to an average of 10-12 W/m-K compared to 14 W/m-K for conventional 316L.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Influence of solidification accelerators on structure formation of anhydrite-containing binders

The article presents results of scientific analysis of chemical additives influence on acid fluoride binder. It was found that the influence of sulfate nature additives on the process of hydration and solidification of the binder is similar to influence of additives on indissoluble anhydrite. Additives with SO{sub 4}{sup 2−} anion NO{sup −} are more efficient. The mentioned additives according to accelerating effect belong to the following succession: K{sub 2}SO{sub 4} > Na{sub 2}SO{sub 4} > FeSO{sub 4} > MgSO{sub 4}. Facilitation of the process of hydration and solidification of the binder, increase in density and durability of the binder (32 MPa) is to the greatest extent achieved with the introduction of 2% sodium sulfate additive of the binder’s mass into the composition of the binder along with the ultrasonic treatment of water solution. Directed crystal formation process with healing of porous structure by new growths presented as calcium sulfate dehydrate and hydroglauberite provides positive effect.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Effects of Transition Layer on Bending Resistance in Copper-Clad Aluminum Composite Casting

The performance of the transition layer in a Cu/Al composite casting directly affects the quality of subsequent plastic deformation processing; however, there are no universal or standardized measurement indices for the performance of the transition layer. In this study, Cu/Al composite castings were prepared using the pouring aluminum method, and the resulting solidification microstructures on the bending resistance were investigated. The results of this study lay a theoretical foundation for the development of the plastic processing technologies of these composite castings. A thinner transition layer in the Cu/Al composite casting led to improved bending resistance. In addition, for a fixed total thickness of the transition layer, the bending resistance was mainly controlled by the γ/β interface and β + eutectic (α + β) microstructure, and the thickness of the γ phase had a negligible effect on the bending resistance. The γ/β interface cracked first when the transition layer bore the tensile and shear stress during the bending process, which resulted in the transition layer easily separating from the copper. The bending resistance of the transition layer can be feasibly judged by measuring the bending angle of the specimen tip, which can be easily performed when the specimen bends toward the aluminum direction, suggesting that our proposed method has considerable practical significance.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of Undercooling and Cooling Rate on Peritectic Phase Crystallization Within Ni-Zr Alloy Melt

The liquid Ni-16.75 at. pct Zr peritectic alloy was substantially undercooled and containerlessly solidified by an electromagnetic levitator and a drop tube. The dependence of the peritectic solidification mode on undercooling was established based on the results of the solidified microstructures, crystal growth velocity, as well as X-ray diffraction patterns. Below a critical undercooling of 124 K, the primary Ni{sub 7}Zr{sub 2} phase preferentially nucleates and grows from the undercooled liquid, which is followed by a peritectic reaction of Ni{sub 7}Zr{sub 2}+L → Ni{sub 5}Zr. The corresponding microstructure is composed of the Ni{sub 7}Zr{sub 2} dendrites, peritectic Ni{sub 5}Zr phase, and inter-dendritic eutectic. Nevertheless, once the liquid undercooling exceeds the critical undercooling, the peritectic Ni{sub 5}Zr phase directly precipitates from this undercooled liquid. However, a negligible amount of residual Ni{sub 7}Zr{sub 2} phase still appears in the microstructure, indicating that nucleation and growth of the Ni{sub 7}Zr{sub 2} phase are not completely suppressed. The micromechanical property of the peritectic Ni{sub 5}Zr phase in terms of the Vickers microhardness is enhanced, which is ascribed to the transition of the peritectic solidification mode. To suppress the formation of the primary phase completely, this alloy was also containerlessly solidified in free fall experiments. Typical peritectic solidified microstructure forms in large droplets, while only the peritectic Ni{sub 5}Zr phase appears in smaller droplets, which gives an indication that the peritectic Ni{sub 5}Zr phase directly precipitates from the undercooled liquid by completely suppressing the growth of the primary Ni{sub 7}Zr{sub 2} phase and the peritectic reaction due to the combined effects of the large undercooling and high cooling rate.

36 MATERIALS SCIENCE↗
DOE OSTI2017

HPC Institutional Computing Project: W15_lesreactiveflow KIVA-hpFE Development: A Robust and Accurate Engine Modeling Software

KIVA-hpFE is a high performance computer software for solving the physics of multi-species and multiphase turbulent reactive flow in complex geometries having immersed moving parts. The code is written in Fortran 90/95 and can be used on any computer platform with any popular complier. The code is in two versions, a serial version and a parallel version utilizing MPICH2 type Message Passing Interface (MPI or Intel MPI) for solving distributed domains. The parallel version is at least 30x faster than the serial version and much faster than our previous generation of parallel engine modeling software, by many factors. The 5th generation algorithm construction is a Galerkin type Finite Element Method (FEM) solving conservative momentum, species, and energy transport equations along with two-equation turbulent model k-ω Reynolds Averaged Navier-Stokes (RANS) model and a Vreman type dynamic Large Eddy Simulation (LES) method. The LES method is capable modeling transitional flow from laminar to fully turbulent; therefore, this LES method does not require special hybrid or blending to walls. The FEM projection method also uses a Petrov-Galerkin (P-G) stabilization along with pressure stabilization. We employ hierarchical basis sets, constructed on the fly with enrichment in areas associated with relatively larger error as determined by error estimation methods. In addition, when not using the hp-adaptive module, the code employs Lagrangian basis or shape functions. The shape functions are constructed for hexahedral, prismatic and tetrahedral elements. The software is designed to solve many types of reactive flow problems, from burners to internal combustion engines and turbines. In addition, the formulation allows for direct integration of solid bodies (conjugate heat transfer), as in heat transfer through housings, parts, cylinders. It can also easily be extended to stress modeling of solids, used in fluid structure interactions problems, solidification, porous media modeling and magneto hydrodynamics.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Laser repair welding of irradiated alloy 182

Welding repair of irradiated nickel-based alloys, such as Alloy 182, poses a significant challenge due to helium-induced cracking (HeIC) and grain boundary degradation (GBD) in the heat affected zone, driven by helium accumulation at grain boundaries and welding-induced tensile stresses. This study investigates the weldability of irradiated Alloy 182 up to 15 wppm doped boron using both conventional laser welding and the Auxiliary Beam Stress Improved (ABSI) laser welding technique. While HeIC was observed at the weld toe of the entry pass in both methods due to the higher effective heat input associated with the initial pass directly on the base metal, no additional cracking occurred elsewhere, even at elevated helium concentrations. Optical and scanning electron microscopy analysis revealed that the ABSI technique, which introduces additional compressive stresses to counteract solidification-induced tensile stresses, significantly reduced GBD formation, lowering its total count from 1,230 to 339 and decreasing both average and maximum GBD lengths. In conclusion, these results demonstrate that the ABSI technique is a promising approach to mitigate helium-induced damage and improve the weldability of irradiated Alloy 182, offering a viable solution for structural repairs for long-term operation of existing nuclear reactors.

grain boundary degradation↗