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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Crystal nucleation in Pd-Si alloys

A study of the crystal phase nucleation in undercooled droplets of Pd-Si alloys with composition near the Pd(84.5)Si(15.5) eutectic composition is reported. Molten droplets are released at the top of a drop tube and solidify (to either a crystalline or glassy state) during descent. This provides a containerless (and nearly gravity free) environment so that nucleation due to container walls or vibrations is eliminated. It is found that crystallization, due to homogeneous nucleation, is bypassed in droplets of 1 mm diameter when cooled at 760 K/sec. From this an upper limit of the homogeneous nucleation rate is estimated. Results are compared with a previously published study of nucleation in 0.06 mm to 0.33 mm diameter droplets, which indicated that nucleation results from heterogeneous surface nucleation and that the number of these nuclei is dependent on the atmosphere in the drop tube.

Drehman, A. J.↗
NASA NTRS1985

The volume change during solidification

The liquid-solid phase transformation of solidifying metallic melts is accompanied by a volume change Delta-Vm. This volume change produces a gravity-independent microscopic flow near the solidification front. In a ground-based laboratory, solidification processes are also affected by convection due to temperature and concentration gradients. A quantitative evaluation of the effects of these flows on the formation of structure requires reproducible values of Delta-Vm. Alloys with Delta-Vm = 0 would be best suited for such an evaluation, while alloys with a constant value for Delta-Vm are still usable. Another requirement is related to a solidus-liquidus interval which is as small as possible. One-phase alloys, which would be particularly well suited, could not be found. For these reasons, alloys which solidify in two phases, as for example eutectics, have been considered, taking into account the Al-Ge system. Attention is given to the volume change at the melting point, the measurement of this change, the volume change at solidification, and applications to terrestrial technology.

Rittich, M.↗
NASA NTRS1973

Some possible filler alloys with low vapor pressures for refractory-metal brazing

A compilation of eutectics and melting-point minima for binary combinations of metals having vapor pressures below 10 to the minus 10th power torr at 1500 degrees K and .00005 torr at 2000 degree K is presented. These compositions and others near them on their phase diagrams are potential special brazing fillers for refractory metals. Some possible problems and advantages for fusion bonds of such mixtures are indicated. Evaluations of brazing fillers containing refractory metals are reported.

Morris, J. F.↗
NASA NTRS1975

Preparation of eutectic superalloys by EFG

An attempt was made to produce airfoil shaped bars of three different eutectic superalloys by means of the edge-defined, film-fed growth (EFG) method. The alloys used were a gamma + delta Ni-Cb alloy, a gamma/gamma prime + delta Ni-Cb-Al alloy and a Co-TaC alloy containing Ni and Cr. The development of a new die material was essential in the investigation since these alloys are reactive toward known die materials. Tantalum carbide was selected as a die material because it exhibited spontaneous capillary rise and slow rate of degradation in the liquid metals. Eutectic bars up to 1 mm thick and 6 mm wide were grown from TaC dies in order to determine the growth characteristics and the thermal gradient. Large bars of the gamma/gamma prime + delta alloy were grown and tensile tested. A die with a blind central cavity was designed and several hollow, tear-shaped bars were grown.

Hurley, G. F.↗
NASA NTRS1977

Thermal fatigue and oxidation data of superalloys including directionally solidified eutectics

Thermal fatigue and oxidation data were obtained on 61 specimens, representing 15 discrete alloy compositions or fabricating techniques and three coating systems. Conventionally fabricated alloys included V57, MM 200, Rene 77, Rene 125, MM 246, MM 509, IN-738, IN-792 + Hf, and MM 200 + Hf. The directionally solidified alloys were MM 200, MM 200 single crystal, MM 200 bicrystal, cellular gamma/gamma' - delta) and lamellar gamma/gamma' - delta. The coatings systems included NiCrAlY on IN-738, In-792 + Hf, MM 200 DS, MM 200 DS single crystal, and cellular gamma/gamma' - delta and NiCrAlY/Pt on lamellar gamma/gamma' - delta. Crack initiation survival rates were recorded for all alloys, with and without coatings. All uncoated alloys, except MM 509, exhibited significant oxidation weight loss in 75,000 to 15,000 cycles. MM 509 specimens had weight losses only slightly higher than coated specimens through 7,500 cycles. All coated specimens had low weight loss.

Hill, V. L.↗
DOE OSTI2024

Friction stir processing on a strontium modified, thin-wall, vacuum-assisted high-pressure die-cast Aural-5 alloy to improve tensile and fatigue performance

Here, this study explores the application of friction stir processing (FSP) to enhance the material properties of Sr-modified Aural-5 alloy, with a focus on improved tensile and fatigue properties. Aural-5 is a well-known vacuum-assisted high-pressure die-cast (HPDC) Al-Si7-Mg alloy used in the automotive industry to reduce vehicle weight, enhance fuel efficiency, and lower carbon emissions. This alloy modifies its material chemistry with Sr for fine fibrous networks of eutectic silicon and manganese (Mn) to reduce die soldering. It has significantly less iron (Fe) content resulting in the elimination of detrimental needle-shaped Fe-bearing ß-phase intermetallic and improving ductility. The initial microstructure of as-received HPDC Aural-5 exhibits shrinkage porosity in the middle section, a dendritic microstructure with fibrous Al-Si eutectic colonies, a shear-band structure beneath the die-wall, large dendritic externally solidified crystals (ESCs), needle-shaped Mg 2 Si phase and significant second-phase particulates. Some of those microstructural features, such as porosity, ESCs, needle-shaped Mg 2 Si phase, and large second-phase particles, serve as initiation sites for cracks under mechanical loading, resulting in adverse effects on tensile properties, particularly ductility. FSP effectively transforms the microstructure into a wrought configuration with uniform particle distribution by eliminating porosity and disintegrating dendrites, eutectic colonies, ESCs, second-phase particles, and shear-band structures. FSP-driven microstructure modification enhances yield strength and tensile ductility by ~30% and ~35%, respectively. The fatigue life of the material in a bending mode configuration (stress ratio R = 0.1) after FSP exhibits enhancements ranging from 2.0 to 3.9 times that of the original HPDC Aural-5 alloy, depending on the applied stress level.

36 MATERIALS SCIENCE↗
NASA NTRS1984

The growth of metastable peritectic compounds

The effects of directional solidification processing on the microstructural, compositional, and magnetic properties of high-melting-temperature, commercially important alloys which form from the liquid state via peritectic or eutectic type reactions were determined. Emphasis was placed on ferromagnetic compounds of the commercially important Co-Sm and Al-Mn systems. The primary dendrite spacing for eutectic Sm2Co17/Co scaled with negative square root of V and varied from approximately 50 microns for V 20 cm/h to hundreds of microns for V 10 cm/h. Since the crystal growth mechanism was dendritic rather than cooperative, the assoicated permanent magnet properties were rather poor. Magnetization as a function of sample orientation indicates that the easy axis of magnetization was primarily along the direction of solidification for the eutectic Sm2Co17/Co and peritectic SmCo5/Sm2Co17 compositions. For the Al-Mn case, magnetization and microstructural characterization suggest isotropic, polycrystalling growth for all solidification velocities studied.

Pirich, R. G.↗
NASA NTRS2013

Fatigue Resistance of Liquid-assisted Self-repairing Aluminum Alloys Reinforced with Shape Memory Alloys

A self-repairing aluminum-based composite system has been developed using a liquid-assisted healing theory in conjunction with the shape memory effect of wire reinforcements. The metal-metal composite was thermodynamically designed to have a matrix with a relatively even dispersion of a low-melting eutectic phase, allowing for repair of cracks at a predetermined temperature. Additionally, shape memory alloy (SMA) wire reinforcements were used within the composite to provide crack closure. Investigators focused the research on fatigue cracks propagating through the matrix in order to show a proof-of-concept Shape Memory Alloy Self-Healing (SMASH) technology for aeronautical applications.

Wright, M. Clara↗
NASA NTRS1999

Effect of Growth Rate on Elevated Temperature Plastic Flow and Room Temperature Fracture Toughness of Directionally Solidified NiAl-31Cr-3Mo

The eutectic system Ni-33Al-31Cr-3Mo was directionally solidified at rates ranging from 7.6 to 508 mm/h. Samples were examined for microstructure and alloy chemistry, compression tested at 1200 and 1300 K, and subjected to room temperature fracture toughness measurements. Lamellar eutectic grains were formed at 12.7 mm/h; however cellular structures with a radial eutectic pattern developed at faster growth rates. Elevated temperature compression testing between 10(exp -4) to 10(exp -7)/s did not reveal an optimum growth condition, nor did any single growth condition result in a significant fracture toughness advantage. The mechanical behavior, taken together, suggests that Ni-33Al-31Cr-3Mo grown at rates from 25.4 to 254 mm/h will have nominally equivalent properties.

Whittenberger, J. Daniel↗
DOE OSTI2024

Hypereutectic Al-Ce-X (X=Mn, Cr, V, Mo, W) alloys fabricated by laser powder-bed fusion

Here, we characterize the microstructures and high-temperature mechanical properties of Al-2Ce and ternary Al-2Ce-1X (at.%) alloys fabricated by laser powder-bed fusion (LPBF), where X = Mn, Cr, V, Mo, and W are slow-diffusing transition metals. All ternary alloys show a hypereutectic microstructure in the as-LPBF state, containing an interconnected network of eutectic Al 11 Ce 3 phases (~10 vol.%) and an additional population of submicron, equiaxed Al 20 CeX 2 primary precipitates (~10 vol.%) which are isomorphous among these five alloys. Similar microstructures are present in arc-melted rods and atomized powders but are coarser due to the slower cooling rates in these processes. The hardness of the as-LPBF ternary Al-Ce-X alloys (1300–1400 MPa) is higher than that of the binary Al-Ce alloy (~1100 MPa) due to the higher volume fraction of strengthening phases. Furthermore, during exposure at 400 °C for up to three months, greater hardness retention is achieved in the ternary Al-Ce-X alloys (65–75%) than in the binary Al-Ce alloy (~55%), which is attributed to the extreme coarsening resistance of the Al 20 CeX 2 precipitates imparted by the very slow-diffusing ternary solute. These coarsening-resistant Al 20 CeX 2 precipitates also substantially improve alloy creep resistance, increasing the threshold stress for dislocation creep at 300°C from ~32 MPa for the binary Al-Ce alloy to ~77–100 MPa for the ternary Al-Ce-X alloys, and at 400°C from <10 MPa for the binary Al-Ce alloy to >40 MPa for the ternary Al-Ce-V alloy.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Low vapor pressure braze alloys for thermionic energy converters

The evaluation of cesium diode electrode materials called for braze fillers with very low vapor pressures and a wide range of melting points. Binary alloys of low vapor pressure refractory metals were chosen to fill this need. These alloys of Th, Zr, Hf, Ru, Nb, Ir, Mo, Ta, Os, Re, and W have reported melting point minima or eutectics from 1,510 K to above 3,000 K. Preliminary data are compiled on the use of several of these braze alloys. Melting points and surface wetting on a Ta base are given. Results of brazing Ir, LaB6, Nb, Re, W, and Zr-22 wt % ZrO2 materials into Ta and Nb-1% Zr bases are presented. Current braze usage is summarized.

Bair, V. L.↗
NASA NTRS1989

Improving the low temperature ductility of NiAl

As part of a study aimed at developing a ductile NiAl-based alloy, ingots of Ni-Fe-Al alloys were cast and hot extruded to rods. The purpose of the iron additions was two-fold viz; to produce a change in the slip vector from 001 to 111 line and, in one alloy, to add a L1(2)-structured ductile second phase. Extruded Ni-20Al-30Fe was two-phase, containing a pro-eutectic B2 phase in a fine lamellar structure of B2+L1(2) phases. Room temperature tensile testing of both single extruded and double extruded alloys resulted in 8-percent and 22-percent plastic elongation and yield stresses of 850 and 760 MPa, respectively. Fracture in both cases occurred by ductile tearing of the eutectic and transgranular cleavage of the proeutectic phase at 1350 MPa. The ductility in double extruded condition is higher than that reported earlier in rapidly solidified wires by Inoue et al. (1984). By comparison, extruded single-phase B2-structured Ni-30Al-20Fe exhibited a fracture strength of 780 MPa, no plasticity, and a mixture of intergranular fracture and transgranular cleavage. This is contrast to earlier work by Inoue et al. where a yield stress of 400 MPa, 5 percent plastic strain, and a mixture of dimple and intergranular fracture was reported.

Guha, Sumit↗
NASA NTRS2017

Solidification and Morphological Evolution of Al-Si Eutectics in Convector-Diffusive Conditions

The Al-Si material system is an important and has been studied for over half century with a focus on industrial applications in high strength and high conductivity alloys. A great deal of researches have been focused on controlling the morphology and hence performance through the addition of small impurities and by processing conditions. Most of the structure-property correlations are based on the post solidified micromorphology and growth conditions. This material system is unique and has been explored for heat spreader, controlling coefficient of expansion by adjusting composition of silicon and in designing composites. The Al-Si system is very interesting system for understanding the dendritic (Al-rich side) eutectic transition. Recently this system has been of great interest because of its applications in designing heat spreader, low temperature flux to grow SiC large substrates and in controlling the coefficient of expansion of Al-based alloys. We have performed extensive experiments to understand eutectic transition and to understand the morphological evolution in presence of impurities. We will discuss the results of dendritic transition into faceted long grains in convector-diffusive conditions. In this presentation we will present morphological transition in presence of carbon impurity and development of novel morphology.

Singh, N. B.↗
DOE OSTI2026

Thermal cycling-driven microstructural changes of eutectic Al–Si phase change materials in SS304 containers revealed by multi-modal imaging

Aluminum-based Al–Si alloys are widely used as phase change materials (PCMs) in thermal energy storage (TES) systems owing to their high volumetric latent heat and superior thermal conductivity. However, their long-term reliability is limited by degradation processes that remain insufficiently understood. In this work, we employ a multimodal, correlative characterization framework to systematically resolve the degradation behavior of eutectic Al–Si PCMs in contact with SS304 containers under repeated thermal cycling. By integrating high-resolution electron microscopy, three-dimensional X-ray fluorescence (3D XRF) imaging, and differential scanning calorimetry (DSC), we directly link spatially resolved compositional and microstructural evolution to changes in thermophysical properties. The correlative analysis reveals that elemental leaching of Fe, Cr, and Ni from the stainless-steel container into the PCM drives the formation of intermetallic compounds (IMCs) both at the interface and within the bulk PCM, leading to pronounced compositional heterogeneity. These interfacial reactions and diffusion-induced transformations progressively destabilize the Al–Si eutectic, reducing the effective phase-transforming fraction. Consistent with these observations, DSC measurements show a decrease in melting temperature and latent heat of fusion with thermal cycling. These results underscore the critical influence of interfacial reactions and material compatibility on the stability, durability, and overall performance of Al–Si-based TES systems.

25 ENERGY STORAGE↗
NASA NTRS1991

Controlled Temperature Gradient Improves Freezing Alloy

Controlled gradient of temperature in advancing zone of solidification increases fatigue life of directionally solidified nickel-base superalloy. Improved solidification process eliminates, reduces, or controls microstructure of deleterious brittle phases, including carbides and gamma/gamma prime eutectic. Also reduces microsegregation and makes discrete carbides (if present) become fine and blocky. Expected to improve properties of other alloys, of both directionally-solidified polycrystalline and single-crystal forms.

Schmidt, Deborah↗
DOE OSTI2025

Versatile Cell Design for Molten Fluoride Salt Spectroscopy: Investigating Metal-Ion Speciation in Molten Fluoride Salts

Fluoride-based molten salts are widely used in industrial applications including aluminum production, thermal energy storage, optical crystal growth, and advanced nuclear reactor designs. Despite the wide range of uses, fundamental understandings of coordination chemistry and methods for probing molten fluorides are scarce, likely due to the difficulty of probing fluoride melts with spectroscopic techniques. Performing spectroscopic measurements of fluoride-based salts is challenging due to the highly corrosive nature of these salts, which can degrade many common optical materials. Here, in this work, we present a versatile optical cell design that enables spectroscopic measurements of corrosive melts. This innovative cell design overcomes the challenges posed by the corrosive nature of the salts, allowing for an accurate and consistent spectroscopic analysis. This work reports temperature-dependent absorption measurements for Co 2+ , Ni 2+ , and Cr 3+ analytes in LiF-NaF-KF eutectic salt (i.e., FLiNaK), which are common corrosion products originating from structural alloys in molten-fluoride handling. Absorption spectra were used to understand interactions of these analytes with FLiNaK, particularly ligand field coordination. The analysis of absorption spectra was complemented by structural analyses using ab initio molecular dynamics (AIMD) simulations, providing deeper insights into the behavior of the analytes in FLiNaK. Our findings indicate that the analytes studied in this work exist in octahedral or near-octahedral coordination states that remain stable across the temperature range of 500–600 °C. This work not only highlights an applied solution to performing optical spectroscopy in corrosive, high-temperature melts but also provides important fundamental insight on coordination behavior of transition-metal species in molten fluorides.

Fluoride salt spectroscopy↗
NASA NTRS1973

Microstructural study of the nickel-base alloy WAZ-20 using qualitative and quantitative electron optical techniques

The NASA nickel-base alloy WAZ-20 was analyzed by advanced metallographic techniques to qualitatively and quantitatively characterize its phases and stability. The as-cast alloy contained primary gamma-prime, a coarse gamma-gamma prime eutectic, a gamma-fine gamma prime matrix, and MC carbides. A specimen aged at 870 C for 1000 hours contained these same constituents and a few widely scattered high W particles. No detrimental phases (such as sigma or mu) were observed. Scanning electron microscope, light metallography, and replica electron microscope methods are compared. The value of quantitative electron microprobe techniques such as spot and area analysis is demonstrated.

Young, S. G.↗
NASA NTRS2001

Effects of Minor Alloying Additions on the Microstructure, Toughness, and Creep Strength of Directionally Solidified NiAl-31Cr-3Mo

A study of the effects of small (0.25 to 1.0 at%) fifth element additions to the structure and mechanical properties of directionally solidified (DS) NiAl-31Cr-3Mo has been undertaken. Essentially all the additions changed the as-DS'ed microstructure from lamellar eutectic grains to cells and, in some cases, introduced NiAl dendrites and/or third phases. In general the alloying additions did not improve strength or toughness over that possessed by the base composition; only Hf and, perhaps Ti, gave a minor increase in elevated temperature creep resistance. The lack of improvement in creep properties is probably due to inability to precipitation harden NiAl.

Whittenberger, J. D.↗