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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Natural convection in steady solidification - Finite element analysis of a two-phase Rayleigh-Benard problem

Galerkin finite-element approximations and Newton's method for solving free boundary problems are combined with computer-implemented techniques from nonlinear perturbation analysis to study solidification problems with natural convection in the melt. The Newton method gives rapid convergence to steady state velocity, temperature and pressure fields and melt-solid interface shapes, and forms the basis for algebraic methods for detecting multiple steady flows and assessing their stability. The power of this combination is demonstrated for a two-phase Rayleigh-Benard problem composed of melt and solid in a veritical cylinder with the thermal boundary conditions arranged so that a static melt with a flat melt-solid interface is always a solution. Multiple cellular flows bifurcating from the static state are detected and followed as Rayleigh number is varied. Changing the boundary conditions to approach those appropriate for the vertical Bridgman solidification system causes imperfections that eliminate the static state. The flow structure in the Bridgman system is related to those for the Rayleigh-Benard system by a continuous evolution of the boundary conditions.

Chang, C. J.↗
NASA NTRS2000

An Experimental and Mathematical Study to Evaluate the Role of Ultrasonic Energy in Promoting Microstructural Uniformity During Controlled Directional Solidification Processing

There are many commercially relevant metal and non-metal "alloy" systems that separate into two different liquids upon cooling from a higher temperature. Consequently during solidification processing the inherent density differences between the two liquid phases leads to rapid, gravity driven, separation and severe segregation, a factor that significantly compromises the desired material properties. Processing in a microgravity environment minimizes settling but segregation still occurs due to gravity independent wetting and coalescence phenomena. This presentation reports on experiments that utilized succinonitrile-glycerol mixtures, a transparent system that 1) separates into two liquids upon cooling and 2) is also well established as an analogue to solidification phenomena observed in metals. Segregation was significantly reduced when the mixtures were subjected to ultrasonic energy during directional solidification processing. The processing parameters introduced by this application have been evaluated in view of optimizing dispersion uniformity. The improvement is in good agreement with a novel model that 1) predicts the achievable size of the droplets as a function of applied ultrasonic energy and then 2) calculates their relative sinking velocity through the bulk liquid.

Grugel, R. N.↗
NASA NTRS1993

Stable Ni isotopes and Be-10 and Al-26 in metallic spheroids from Meteor Crater, Arizona

The Canyon Diablo spheroids, which are found around Meteor Crater, Arizona, are nickel-enriched objects with diameters from less than 0.1 to several mm. Previous studies have suggested that the enrichment of nickel resulted either from shock-melting of S-rich areas followed by solidification of the liquids under strongly non-equilibrium conditions at rapid cooling rates during flight outward from the crater or from the selective oxidation of iron. Isotopic studies are an effective tool for constraining the degree of open-system evaporation experienced by a system. The purpose of this study was to see whether Ni isotopes had been fractionated by volatilization during spheroid formation. In addition, the cosmogenic nuclides Be-10 and Al-26 were measured to try to estimate the depths in the parent meteorite from which the spheroids came.

Xue, S.↗
DOE OSTI2025

Interpreting dynamic-compression experiments to uncover the time dependence of freezing: Application to gallium

Using pulsed-power magnetic field sources to compress gallium to gigapascal pressures on nanosecond timescales, we report here experiments on shockless dynamic compression of a liquid metal. Time-resolved velocimetry data reveal signatures of rapid freezing from a metastable liquid state, and we demonstrate that the kinetics of this nonequilibrium solidification can be accurately simulated with a computational modeling framework we have developed in previous studies, where classical nucleation theory is coupled with hydrodynamics. Notably, velocity traces in some of our experiments show evidence of a phase transition, while others do not, even though other types of evidence suggest that solidification may be occurring in all of them. We explain how predictions made by our models regarding the presence or absence of these phase-transition signatures motivated additional experiments that later confirmed the theoretical predictions. Our analysis shows that due to the rapid, quasi-isentropic nature of the loading path, our experiments were able to compress liquid gallium to metastable states that are undercooled below the equilibrium melt temperature by more than 300 K and exhibit pressures that approach five times the equilibrium melt pressure. The understanding gained in this study should form the basis for future dynamic-compression experiments aimed at interrogating melt curves at high pressures.

gallium↗
NASA NTRS1993

FE-60 and the evolution of eucrites

We have recently presented evidence for the existence of live Fe-60 in the early solar system. This evidence comes from observations of 2.4 to 50 epsilon unit (1 part in 10(exp 4)) relative excesses of Ni-60 measured in samples from the eucrite Chervony Kut (CK). These isotopic excesses have been produced by the decay of the short-lived radionuclide Fe-60 (T(sub 1/2) = 1.5 Ma). Because CK originates from a planetesimal which was totally molten and its high Fe/Ni ratio is due to a planet-wide Fe-Ni fractionation during metal-silicate segregation, the presence of the Fe-60 decay product indicates the large scale abundance of Fe-60 in the early solar system and its presence during differentiation of this planetesimal. The observed variable Ni-60 excesses in different bulk samples and mineral separates from CK can only be understood if some Fe-60 was still alive at the time when basaltic magma had solidified on the eucrite parent body. The lack of a correlation between Ni-60 and the respective Fe/Ni ratios in different mineral fractions from CK indicates a metamorphic remobilization of Ni after essentially all Fe-60 has decayed. However, Ni-60 from three bulk samples from different locations within the meteorite appears to correlate reasonably well with the respective Fe/Ni ratios. If we regard this correlation as an isochron then its slope yields a Fe-60/Fe-56 ratio f (3.9 +/- 0.6) x 10(exp -9) and an initial Ni-60 of 3.2 plus or minus 0.9 epsilon units at the time of crystallization of CK. Estimates based on these values and a approximately 10 Ma time interval between CK solidification and formation of the earliest condensates in the solar system followed by rapid accretion of planetary bodies indicate that the decay of Fe-60 could produce sufficient heat to melt these planetesimals. If Al-26 was present on a planetary scale as Fe-60 and at abundances close to values observed in Allende inclusions then melting of small early formed planets is inevitable. As an attempt to further explore the Fe-60/Ni-60 isotope system as an early solar system chronometer we studied another noncumulate eucrite, Juvinas (JUV) (sample USNM 1051), which belongs to the same subgroup as CK.

Shukolyukov, A.↗
NASA NTRS1995

Thermal spray processing

Thermal spray processing has been used for a number of years to cost-effecticely apply TBC's for a wide range of heat engine applications. In particular, bond coats are applied by plasma spray and HVOF techniques and partially-stabilized zirconia top coats are applied by plasma spray methods. Thermal spray involves melting and rapid transport of the molten particles to the substrate, where high-rate solidification and coating build-up occur. It is the very nature of this melt processing that leads to the unique layered microstructure, as well as the apparent imperfections, so readily identified with thermal spray. Modeling the process, process-induced residual stresses, and thermal conductivity will be discussed in light of a new understanding of porosity and its anisotropy. Microcracking can be understood using new approaches, allowing a fuller view of the processing-performance connection. Detailed electron microscopic, novel neutron diffraction and fracture analysis of the deposits can lead to a better understanding of how overall microstructure can be controlled to influence critical properties of the deposited TBC system.

Herman, H.↗
NASA NTRS1984

The potential for bulk undercooling as an industrial process

The main focus is on solidification occurring in highly supercooled melts. Solidification rates in such melts are extremely high, an attractive feature from a commercial standpoint. Thus, the reported growth velocities for pure Ni and Co dendrites at a supercooling of 175 K are in excess of 180 km/hr. Rapidly quenched crystalline alloys produced by various atomization processes (e.g., centrifugal atomization or inert gas atomization) or melt spinning are examples of solidification processes, currently being intensively explored commercially, wherein extremely high solidification rates are achieved. Estimated dendrite tip growth rates are about 2 km/hr in a binary Al-4.5 wt % alloy, with a heat transfer coefficient of 6.4x10 sub 5 w/sq cm K or 15 cal/cu cm sK. In the limit, when the solidification rate exceeds a critical value, a glassy microstructure is obtained even in highly alloyed melts, which under normal conditions would solidity to form one or more crystalline phases. Glassy metals, also called metallic glasses, are candidate materials for distribution transformers because of their very low energy losses and are also being used in brazing and soldering applications.

Laxmanan, V.↗
NASA NTRS1993

Magnetic fields of the terrestrial planets

The four terrestrial planets, together with the Earth's Moon, provide a significant range of conditions under which dynamo action could occur. All five bodies have been visited by spacecraft, and from three of the five bodies (Earth, Moon and Mars) we have samples of planetary material upon which paleomagnetic studies have been undertaken. At the present time, only the Earth and Mercury appear to have a significant dipole magnetic field. However, the Moon, and possibly Mars, appear to have had ancient planetary dynamos. Venus does not now have a significant planetary magnetic field, and the high surface temperatures should have prevented the recording of evidence of any ancient magnetic field. Since the solidification of the solid inner core is thought to be the energy source for the terrestrial magnetic field, and since smaller bodies evolve thermally more rapidly than larger bodies, we conjecture that the terrestrial planets are today in three different phases of magnetic activity. Venus is in a predynamo phase, not having cooled to the point of core solidification. Mercury and the Earth are in the middle of their dynamo phase, with Mercury perhaps near the end of its activity. Mars and the Moon seem to be well past their dynamo phase. Much needs to be done in the study of the magnetism of the terrestrial planets. We need to characterize the multipole harmonic structure of the Mercury magnetic field plus its secular variation, and we need to analyze returned samples to attempt to unfold the long-term history of Mercury's dynamo. We need to more thoroughly map the magnetism of the lunar surface and to analyze samples obtained from a wider area of the lunar surface. We need a more complete survey of the present Martian magnetic field and samples from a range of different ages of Martian surface material. Finally, a better characterization of the secular variation of the terrestrial magnetic field is needed in order to unfold the workings of the terrestrial dynamo.

Russell, C. T.↗
NASA NTRS1984

Bulk undercooling

Bulk undercooling methods and procedures will first be reviewed. Measurement of various parameters which are necessary to understand the solidification mechanism during and after recalescence will be discussed. During recalescence of levitated, glass-encased large droplets (5 to 8 mm diam) high speed temperature sensing devices coupled with a rapid response oscilloscope are now being used at MIT to measure local thermal behavior in hypoeutectic and eutectic binary Ni-Sn alloys. Dendrite tip velocities were measured by various investigators using thermal sensors or high speed cinematography. The confirmation of the validity of solidification models of bulk-undercooled melts is made difficult by the fineness of the final microstructure, the ultra-rapid evolution of the solidifying system which makes measurements very awkward, and the continuous modification of the microstructure which formed during recalescence because of precipitation, remelting and rapid coarsening.

Kattamis, T. Z.↗
NASA NTRS1986

Studying Crystal Growth With the Peltier Effect

Peltier interface demarcation (PID) shown useful as aid in studying heat and mass transfer during growth of crystals from molten material. In PID, two dissimilar "metals" solid and liquid phases of same material. Current pulse passed through unidirectionally solidifying sample to create rapid Peltier thermal disturbance at liquid/solid interface. Disturbance, measured by thermocouple stationed along path of solidification at or near interface, provides information about position and shape of interface.

Larsen, David J., Jr.↗
NASA NTRS1992

The transition from columnar to equiaxed dendritic growth in proeutectic, low-volume fraction copper, Pb-Cu alloys

Lead, 17.1, 11.2, and 5 volume fraction copper (14, 9, and 4 wt pct Cu) alloys have been directionally solidified at constant growth velocities ranging from 1 to 100 microns/s. Serially increasing the growth velocity within this range results in a graded microstructural transition from fully columnar, albeit segregated, copper dendrites in a lead matrix to one consisting only of equiaxed grains. The imposed velocity necessary to effect fully equiaxed growth is found to drop rapidly as the volume fraction of copper is decreased. Factors which complicate the controlled, directional solidification of these alloys are discussed and the experimental results are interpreted in view of, and seen to be in qualitative agreement with, Hunt's theory on the transition from columnar to equiaxed growth of dendrites.

Kim, Shinwoo↗
NASA NTRS2001

Phase Field Modeling of Microstructure Development in Microgravity

This newly funded project seeks to extend our NASA-sponsored project on modeling of dendritic microstructures to facilitate collaboration between our research group and those of other NASA investigators. In our ongoing program, we have applied advanced computational techniques to study microstructural evolution in dendritic solidification, for both pure isolated dendrites and directionally solidified alloys. This work has enabled us to compute dendritic microstructures using both realistic material parameters and experimentally relevant processing conditions, thus allowing for the first time direct comparison of phase field computations with laboratory observations. This work has been well received by the materials science and physics communities, and has led to several opportunities for collaboration with scientists working on experimental investigations of pattern selection and segregation in solidification. While we have been able to pursue these collaborations to a limited extent, with some important findings, this project focuses specifically on those collaborations. We have two target collaborations: with Prof. Glicksman's group working on the Isothermal Dendritic Growth Experiment (IDGE), and with Prof. Poirier's group studying directional solidification in Pb-Sb alloys. These two space experiments match well with our two thrusts in modeling, one for pure materials, as in the IDGE, and the other directional solidification. Such collaboration will benefit all of the research groups involved, and will provide for rapid dissemination of the results of our work where it will have significant impact.

Dantzig, Jonathan A.↗
DOE OSTI2025

Laser Powder Directed Energy Deposition of Steels for Nuclear Applications

This comprehensive investigation examines the structure–property relationships in two nuclear alloy systems—Alloy 709 (A709) austenitic stainless steel and Grade 92 (G-92) ferritic/martensitic (F/M) steel—manufactured via directed energy deposition (DED) for sodium-cooled fast reactor applications. This study establishes the fundamental mechanisms for controlling microstructures for optimizing the mechanical performance of additively manufactured nuclear materials through systematic heat treatment optimization and multiscale characterization. As-deposited A709 steel develops a complex multiscale strengthening architecture consisting of a fine cellular solidification structure with diameter of 2-3 µm within10–50 µm grains, elevated dislocation densities from rapid thermal cycling, and grain boundary precipitates that activate concurrent Hall–Petch, dislocation, and precipitation hardening mechanisms to achieve exceptional properties [yield strength (YS): 603 MPa, ultimate tensile strength (UTS): 844 MPa, Vickers hardness: 220 HV] that achieve a 44% superior strength compared to that of the wrought material. Heat treatments produce different results. Solution annealing (SA) dissolves the cellular structure and reduces the hardness to 190 HV. Precipitation treatment (PT) keeps the cellular structure but adds carbides, allowing the hardness to reach 205 HV. The best approach combines both treatments (SA+PT) and creates uniform precipitate distributions with M 23 C 6 carbides at the grain boundaries and MX carbonitrides in the matrix, achieving a hardness of 195 HV. However, directional differences persist, with a 12%–15% strength variation between orientations due to the inherited layered microstructural architecture that survives aggressive heat treatment. While tensile testing at 550°C demonstrates 40%–50% thermal softening with dynamic strain aging, DED A709 steel still maintains a 71% higher YS than that of the wrought material. Ion irradiation studies (100–400 dpa) of DED A709 steel reveal progressive radiation damage with increasing void density and radiation-induced segregation causing nickel enrichment and chromium depletion, which will ultimately compromise mechanical properties. As-deposited G-92 exhibits exceptional strength (UTS: 1650–1700 MPa, 430 HV) through a complex microstructure containing both ferrite and martensite phases, a high geometrically necessary dislocation (GND) density (17.04×10 14 /m 2 ), and fine carbides. Heat treatments create distinct changes. Normalizing produces fresh martensite with the highest hardness (460 HV) and an increased GND density (20.23×10 14 /m 2 ). Tempering develops dual precipitation systems and reduces the hardness to 290 HV. The optimal approach uses sequential normalizing plus tempering, achieving balanced properties with the lowest hardness (250 HV) and a reduced GND density (11.01×10 14 /m 2 ). A processing-dependent anisotropy is observed: horizontal specimens achieve superior ductile behavior, while vertical specimens exhibit brittle failure. A tempering heat treatment successfully mitigates this anisotropic behavior by transforming the hard martensitic as-deposited structure into tempered martensite enabling both horizontal and vertical specimens to exhibit similar stress–strain characteristics with visible necking behavior. Remarkably, testing at 550°C reveals a reversal in the anisotropy, where as-deposited specimens achieve near isotropy with superior thermal stability (a 15%–20% strength reduction), while tempered specimens develop an orientation dependence with a 25%–30% strength reduction. Both alloy systems demonstrate that DED processing creates specimens with a superior strength through refined microstructural features, though with distinct strengthening mechanisms—austenitic through cellular structures and precipitates versus F/M through phase transformations and precipitates. Heat treatment optimization requires alloy-specific approaches, with A709 benefiting from controlled precipitation while G-92 requires careful phase transformation control. The results show that DED manufacturing can produce nuclear materials with exceptional performance, but directional effects and temperature-dependent behavior must be carefully considered for reactor component design and qualification.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1979

High-gradient continuous-casting furnace

High gradient allows rapid growth rates in directionally-solidified eutectic alloys. Furnace design permits cost reductions in directional solidification process through its increased solidification rates, which reduces melt/mold interaction. It produces structural engineering materials for any application requiring properties directionally-solidified eutectic materials.

Scheuermann, C. M.↗
NASA NTRS1977

Mixing of two liquid metals on spar payload due to spin-up and spin-down

Unexpected results from SPAR experiments, directed at obtaining fine dispersions of metal systems that in a 1-g environment tend to segregate very rapidly, were considered. The physical processes occurring in fluid samples, such as the SPAR samples before solidification, were shown to be insufficient to produce a well mixed liquid by the time solidification was initiated. This would result in solidified samples with the type of segregation noted in the SPAR samples. Experimental evidence and analytical arguments are presented.

Schafer, C. F.↗
NASA NTRS1989

Mixed gravity mode growth during directional dendritic solidification aboard the KC-135

NASA's KC-135, which flies a cyclic parabolic route designed to furnish periods of low gravity alternating with periods of high gravity, has been used to directionally solidify a superalloy and a FE-C-Si alloy. Probable transient effects, due to the rapid changes in the gravity levels, must be taken into account. An effort is presently made to show that experimental design is especially critical in the case of dendritic directional solidification experiments in which mixed gravity modes occur; inappropriate design easily leads to anomalous structures and data.

Grugel, Richard N.↗
NASA NTRS1974

Liquid-metal atomization for hot working preforms

Rapid quenching of a liquid metal by atomization or splat cooling overcomes the major limitation of most solidification processes, namely, the segregation of alloying elements, impurities, and constituent phases. The cooling rates of different atomizing processes are related to the dendrite arm spacings and to the microstructure of the atomized powders. The increased solubility limits and the formation of metastable compounds in splat-cooled alloys are discussed. Consolidation of the powders by hot isostatic compaction, hot extrusion, or hot forging and rolling processes yields billets with properties equivalent to or better than those of the wrought alloys. The application of this powder processing technology to high-performance alloys is reviewed.

Grant, N. J.↗
NASA NTRS2012

Grain Refinement of Freeform Fabricated Ti-6Al-4V Alloy Using Beam/Arc Modulation

Grain refinement can significantly improve the mechanical properties of freeform-fabricated Ti-6Al-4V alloy, promoting increased strength and enhanced isotropy compared with coarser grained material. Large beta-grains can lead to a segregated microstructure, in regard to both alpha-phase morphology and alpha-lath orientation. Beam modulation, which has been used in conventional fusion welding to promote grain refinement, is explored in this study for use in additive manufacturing processes including electron beam freeform fabrication (EBF(sup 3)) and gas-tungsten arc (GTA) deposition to alter solidification behavior and produce a refined microstructure. The dynamic molten pool size induced by beam modulation causes rapid heat flow variance and results in a more competitive grain growth environment, reducing grain size. Consequently, improved isotropy and strength can be achieved with relatively small adjustments to deposition parameters.

Mitzner, Scott↗