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An outline is given of research on the directional solidification of a liquid, and of the effects of natural convection thereon. Three problems which have been studied are described. Finally, current work on solidification in microgravity conditions is discussed.
This program assisted in the design and implementation of the composite casting demonstration for the Apollo 14 mission. Both flight and control samples were evaluated. Some conclusions resulting from a comparison of the flight and control samples were: (1) Solidification in neither the flight nor control samples was truly directional. (2) Apparent intermittent contact of the melt with the container in the flight samples led to unusual nucleation and growth structures. (3) There was greater uniformity, on a macro scale, of both pores and structural features in the flight sample; presumably the result of the reduced gravity conditions. (4) It seems quite feasible to produce enhanced dispersions of gases and dense phases in a melt which is solidified in reduced gravity. (5) A two-stage heating/cooling cycle may help directional solidification. (6) Sample materials should be selected from materials in which the dispersant fully wets the matrix material. (7) Experiments should be conducted in two modes: (1) where the melt is in good thermal contact with the container, and (2) where the melt is in a free-float condition.
The Pore Formation and Mobility Investigation (PFMI) is being conducted in the Microgravity Science Glovebox (MSG) aboard the International Space Station (ISS) with the goal of understanding bubble generation and interactions during controlled directional solidification processing. Through the course of the experiments, beginning in September 2002, a number of key factors pertinent to solidification processing of materials in a microgravity environment have been directly observed, measured, and modeled. Though most experiments ran uninterrupted, on four separate occasions malfunctions to the PFMI hardware and software were experienced that required crew intervention, including in-space repair. Fortunately, each repair attempt was successful and restored the PFMI apparatus to a fully functional condition. Based on PFMI results and lessons learned, the intent of this presentation is to draw attention to the role ISS experiments/hardware can play in providing insight to potential fabrication processing techniques and repair scenarios that might arise during long duration space transport and/or on the lunar/Mars surface.
The Pore Formation and Mobility Investigation (PFMI) is being conducted in the Microgravity Science Glovebox (MSG) aboard the International Space Station (ISS) with the goal of understanding bubble generation and interactions during controlled directional solidification processing. Through the course of the experiments, beginning in September 2002, a number of key factors pertinent to solidification processing of materials in a microgravity environment have been directly observed, measured, and modeled. Though most experiments ran uninterrupted, on four separate occasions malfunctions to the PFMI hardware and software were experienced that required crew intervention, including in-space repair. Fortunately, each repair attempt was successful and restored the PFMI apparatus to a fully functional condition. Based on PFMI results and lessons learned, the intent of this presentation is to draw attention to the role ISS experiments/hardware can play in providing insight to potential fabrication processing techniques and repair scenarios that might arise during long duration space transport and/or on the lunar/Mars surface.
The possibilities of using the low-gravity space environment for the processing of directionally solidified materials in order to remove the limitations imposed by the L-g earth environment have led to a careful evaluation of the directional solidification process and the results commonly obtained. Defects in the regularity of the microstructure have been identified as one of the most important areas where present processing technology needs to be improved. One-g environment material processing must also be carefully characterized before it can be determined if zero-g processing will produce significant benefits in eutectic and off-eutectic solidification. It is suggested that a combination of experimental and analytical thermal studies will be required to optimize the solidification process in order to minimize the structural defects which occur due to present processing techniques.
A linear-stability analysis is performed on the interface formed during the directional solidification of a dilute binary alloy in the presence of a time-periodic flow. In general, the flow is generated by the elliptical motion of the crystal parallel to the interface. The presence of the flow can either stabilize or destabilize the system relative to the case without flow with the result depending on the frequency and amplitude of the oscillations as well as the properties of the material. In the particular, we find that the morphological instability present in the absence of flow can be entirely suppressed with respect to disturbances of the same frequency as the oscillation.
Computer programs are developed and used in the study of the combined effects of evaporation and solidification in space processing. The temperature and solute concentration profiles during directional solidification of binary alloys with surface evaporation were mathematically formulated. Computer results are included along with an econotechnical model of crystal growth. This model allows: prediction of crystal size, quality, and cost; systematic selection of the best growth equipment or alloy system; optimization of growth or material parameters; and a maximization of zero-gravity effects. Segregation in GaAs crystals was examined along with vibration effects on GaAs crystal growth. It was found that a unique segregation pattern and strong convention currents exist in GaAs crystal growth. Some beneficial effects from vibration during GaAs growth were discovered. The implications of the results in space processing are indicated.
This document covers research results from the KC-135 Materials Science Program managed by MSFC for the period FY87 through FY89. It follows the previous NASA Technical Memorandum for FY84-86 published in August 1988. This volume contains over 30 reports grouped into eight subject areas covering acceleration levels, space flight hardware, transport and interfacial studies, thermodynamics, containerless processing, welding, melt/crucible interactions, and directional solidification. The KC-135 materials science experiments during FY87-89 accomplished direct science, preparation for space flight experiments, and justification for new experiments in orbit.
The generalized problem of determining the temperature and solute concentration profiles during directional solidification of binary alloys with surface evaporation was mathematically formulated. Realistic initial and boundary conditions were defined, and a computer program was developed and checked out. The programs computes the positions of two moving boundaries, evaporation and solidification, and their velocities. Temperature and solute concentration profiles in the semiinfinite material body at selected instances of time are also computed.
Thermotransport (or thermal diffusion, Soret effect) is shown to cause significant amount of segregation during the directional solidification of aluminum-copper eutectic. The concentration changes are predicted quantitatively and they are a function of temperature gradient, rate of melting and solidification and the time of soaking. There is a fair agreement between the experiments and calculations. A process is suggested where these concentration changes may be minimized.
The effect of a forced Couette flow, parallel to a horizontal crystal-melt interface during directional solidification of an alloy of lead containing tin, on the onset of convective and morphological instabilities, is calculated numerically via a linear stability analysis. Such a flow does not affect perturbations with wave vectors perpendicular to the flow. For perturbations with wave vectors parallel to the flow, the onset of morphological instability is somewhat suppressed and thermosolutal convection is greatly suppressed. When instabilities occur, they are oscillatory and correspond to travelling waves. For values of the crystal growth velocity for which mixed morphological and convective modes occur, the presence of a forced flow produces sufficient decoupling to allow otherwise degenerate branches to be identified.
The influence of gravitationally driven thermosolutal convection on the directional solidification of peritectic alloys is considered as well as the relationships between the solidification processing conditions, and the microstructure, chemistry, and magnetic properties of such alloys. Analysis of directionally solidified Pb-Bi peritectic samples indicates that appreciable macrosegregation occurs due to thermosolutal convection and/or Soret diffusion. A peritectic solidification model which accounts for partial mixing in the liquid ahead of the planar solidification interface and describes macrosegregation has been developed. Two-phase dendritic and banded microstructures were grown in the Pb-Bi peritectic system, refined two-phase microstructures have were observed, and candidate formation mechanisms proposed. Material handling, containment, casting, microstructural and magnetic characterization techniques were developed for the Sm-Co system. Alloys produced with these procedures are homogeneous.
Wyle Laboratories is currently designing and fabricating two KC-135 materials processing furnaces for Marshall Space Flight Center. The first of these, called the Rapid Melt/Rapid Quench (RM/RQ) Furnace, will be used to melt and resolidify Cu-, Al-, and Ni-based alloys and composites, all during the 20 to 30 seconds of low gravity (0.1 to 0.001 g) available in a single parabola of the KC-135. In addition, it will be capable of directional solidification of these alloys. The furnace can be configured for either liquid or gas quenching of the samples. The second furnace, called the Polymer Solidification Transparent (PST) Furnace, will use a wide range of sample translation rates to directionally solidify polymers and low-melting-point metals as the KC-135 flies a series of parabolic maneuvers. The use of transparent crucibles and an optics system between the hot and cold zones of the furnace will allow for high-resolution video monitoring of the solid-liquid interface during processing. It is hoped that the development of these two furnaces will lead to significant increases in understanding of interface kinetics, fluid flow, and heat transfer in materials during solidification in a low-gravity environment.
The Sub-Compact Seebeck Furnace (SCSF) is a third generation furnace designed as an experimental facility to study the phenomena of undercooling associated with directional solidification. It is intended to provide a double peak temperature profile along the axial direction with gradient zones at each end. By keeping the temperature in the central portion above the melting point of the sample, and cooling the ends of the furnace, a solid/liquid (S/L) interface can be maintained in each one of the gradient zones. A motorized motion control provides a motion to one-half of the furnace. The undercooling associated with the interface being directionally solidified can thus be studied. Modeling of the temperature profile is important to help assure that the furnace design provides the correct thermal characteristics. The furnace is designed with two halves that telescope. Results of thermal analysis based on an analytical solution using simple assumptions will be presented. The resulting temperature profile will show the salient features of the desired thermal profile and provide the general directions for thermal design. Experimental results will be used to compare with the analytical profile. Approach for numerical modeling to provide more detailed information such as two-dimensional effects will be discussed.
Real-time Seebeck voltage variations in a Sn-Bi melt during directional solidification in the MEPHISTO spaceflight experiment flown on the USMP-3 mission, can be correlated with well characterized thruster firings and an Orbiter Main System (OMS) burn. The Seebeck voltage measurement is related to the response of the instantaneous average melt composition at the melt-crystal interface. This allowed us to make a direct comparison of numerical simulations with the experimentally obtained Seebeck signals. Based on the results of preflight and real-time computations, several well-defined thruster firing events were programmed to occur at specific times during the experiment. In particular, we simulated the effects of the thruster firings on melt and crystal composition in a directionally solidifying Sn-Bi alloy. The relative accelerations produced by the firings were simulated by impulsive accelerations of the same magnitude, duration and orientation as the requested firings. A comparison of the simulation results with the Seebeck signal indicates that there is a good agreement between the two. This unique opportunity allows us, for the first time, to quantitatively characterize actual g-jitter effects on an actual crystal growth experiment and to properly calibrate our models of g-jitter effects on crystal growth.
Real-time Seebeck voltage variations in a Sn-Bi melt during directional solidification in the MEPHISTO spaceflight experiment flown on the USMP-3 mission, have been correlated with well-characterized thruster firings and an Orbiter Main System (OMS) burn. The Seebeck voltage measurement is related to the response of the instantaneous average melt composition at the melt-crystal interface. This allowed us to make a direct comparison of numerical simulations with the experimentally obtained Seebeck signals. Based on the results of preflight and real-time computations, several well-defined thruster firing events were programmed to occur at specific times during the experiment. In particular, we simulated the effects of the thruster firings on melt and crystal composition in a directionally solidifying Sn-Bi alloy. The relative accelerations produced by the firings were simulated by impulsive accelerations of the same magnitude, duration and orientation as the requested firings. A comparison of the simulation results with the Seebeck signal indicates that there is a good agreement between the two. This unique opportunity allows us to make the first quantitative characterization of actual g-jitter effects on an actual crystal growth experiment and to calibrate our models of g-jitter effects on crystal growth.
Directional solidification of water-based solutions has emerged as a versatile technique for templating hierarchical porous materials. However, the underlying mechanisms of pattern formation remain incompletely understood. In this work, we present a detailed derivation and analysis of a quantitative phase-field model for simulating this nonequilibrium process. The phase-field model extends the thin-interface formulation of dilute binary alloy solidification with antitrapping to incorporate the highly anisotropic energetic and kinetic properties of the partially faceted ice-water interface. This interface is faceted in the basal plane normal to the ⟨0001⟩ directions and atomically rough in other directions within the basal plane. On the basal plane, the model reproduces a linear or nonlinear relationship between the interface growth rate and the kinetic undercooling that can be linked to experimental measurements. In both cases, spontaneous parity breaking of the solidification front is observed when the preferred growth direction is aligned with the temperature gradient. This phenomenon leads to the formation of partially faceted ice lamellae that drift laterally in one of the ⟨0001⟩ directions. Here, we demonstrate that the drifting velocity of the ice lamellae is controlled by the kinetics on the basal plane and converges as the thickness of the diffuse solid-liquid interface decreases. Furthermore, we examine the effect of the form of the kinetic anisotropy, which is chosen here such that the inverse of the kinetic coefficient varies linearly from a finite value in the ⟨0001⟩ directions to zero in all other directions within the basal plane, consistent with the assumption that the interface grows in local thermodynamic equilibrium in this plane. Our results indicate that the drifting velocity of ice lamellae is not affected by the slope of this linear relation, and the radius and undercooling at the tip of an ice lamella converge at relatively small slope values. Consequently, the phase-field simulations remain quantitative with computationally tractable choices of both the interface thickness and the slope assumed in the form of the kinetic anisotropy.
Experiments were carried out to study the morphological stability of Bi- 1 atomic % Sn alloys using the MEPHISTO directional solidification apparatus aboard Space Shuttle Columbia (STS-87, launched Nov. 19, 1997) and in ground-based studies. The Seebeck signal and temperature measurements indicate that convection was significant for ground-based studies. In the space-based experiments, interface breakdown was observed at growth velocities of 6.7, 27, and 40 microns/sec, but not at 1.8 and 3.3 microns/sec.