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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Toward Understanding Pore Formation and Mobility during Controlled Directional Solidification in a Microgravity Environment Investigation (PFMI)

The generation and inclusion of detrimental porosity, e.g., pipes and rattails can occur during controlled directional solidification processing. The origin of these defects is generally attributed to gas evolution and entrapment during solidification of the melt. On Earth, owing to buoyancy, an initiated bubble can rapidly rise through the liquid melt and pop at the surface; this is obviously not ensured in a low gravity or microgravity environment. Clearly, porosity generation and inclusion is detrimental to conducting any meaningful solidification-science studies in microgravity. Thus it is essential that model experiments be conducted in microgravity, to understand the details of the generation and mobility of porosity, so that methods can be found to eliminate it. In hindsight, this is particularly relevant given the results of the previous directional solidification experiments conducted in Space. The current International Space Station (ISS) Microgravity Science Glovebox (MSG) investigation addresses the central issue of porosity formation and mobility during controlled directional solidification processing in microgravity. The study will be done using a transparent metal-analogue material, succinonitrile (SCN) and succinonitrile-water 'alloys', so that direct observation and recording of pore generation and mobility can be made during the experiments. Succinonitrile is particularly well suited for the proposed investigation because it is transparent, it solidifies in a manner analogous to most metals, it has a convenient melting point, its material properties are well characterized and, it has been successfully used in previous microgravity experiments. The PFMI experiment will be launched on the UF-2, STS-111 flight. Highlighting the porosity development problem in metal alloys during microgravity processing, the poster will describe: (i) the intent of the proposed experiments, (ii) the theoretical rationale behind using SCN as the study material for porosity generation and migration and, (iii) the experimental protocol for the investigation of the effects of the processing parameters. Photographs of the flight experimental hardware, and the novel sample ampoule, will be exhibited. The experimental apparatus will be described in detail and a summary of the scientific objectives will be presented.

Grugel, Richard N.↗
NASA NTRS1984

SPAR X Technical Report for Experiment 76-22 Directional Solidification of Magnetic Composites

The effects of gravity on Bridgman-Stockbarger directional solidification of off-eutectic Bi/MnBi were studied in reduced gravity aboard the SPAR X flight and compared to normal-gravity investigations and previous eutectic Bi/MnBi SPAR flight experiments. The directional solidification of off-eutectic Bi/MnBi results in either a dendritic structure connected with local cooperative growth or a coupled low volume fraction faceted/non faceted aligned rod eutectic whose Mn macrosegregation, MnBi rod size, interrod spacing, and thermal and magnetic properties are sensitive functions of the solidification processing conditions. Two hypoeutectic and two hypereutectic samples were solidified during 605 sec of furnace travel, with an initial 265 sec low-gravity interval. Comparison Earth-gravity samples were solidified in the same furance assembly under identical processing conditions. Macrosegregation in the low-g samples was consistent with a metastable increase in Mn solubility in the Bi matrix, in partial agreement with previous Bi/MnBi SPAR findings of MnBi volume reduction.

Bethin, J.↗
NASA NTRS1987

Investigation of temperature and concentration oscillations in the directional solidification of Pb-Sn-Te

Directional solidification of the pseudobinary compound semiconductor material Pb sub 1-x Sn sub x Te by the Bridgman crystal growth process will be studied. Natural convection in the molten sample will be visualized with a novel electrochemical cell technique that employs the solid electrolyte material yttria-stabilized zirconia. Mass transfer by both diffusion and convection will be measured by detecting the motion of oxygen tracer in the liquid. Additional applications for electrochemical cells in semiconductor crystal growth are suggested. Unsteady convection in the melt will also be detected by the appearance of temperature oscillations. The purpose of this study is to experimentally characterize the overstable conditions for a Pb sub 1-x Sn sub x Te melt in the vertical Bridgman crystal growth technique and use a linear analysis to predict the onset of convection for this system.

Anderson, T. J.↗
NASA NTRS1988

Directional solidification with heat losses

The upward directional solidification of a dilute binary alloy in a tall, thin, two-dimensional slot is considered. Heat losses from the sidewalls produce curved isotherms, interface deformations, and melt convection. An asymptotic approach is used which relates the small heat loss to the thinness of the solidification cell, and solutions are obtained for the resulting melt convection, interface deflection, and the distribution of heat and solute. The model is compared to the numerical results of Chang and Brown (1983) which exclude the effects of solute buoyancy and thermodynamic equilibrium at the interface. The radial segregation at the interface (consistent with both interface shapes and temperature fields) is computed, and it is found that the radial segregation is independent of interfacial shapes; the radial segregation cannot be calculated from only a knowledge of the interface shape.

Brattkus, K.↗
NASA NTRS1991

Experimental study of directional solidification of aqueous ammonium chloride solution

Directional solidification experiments have been carried out using the analog casting system of NH4Cl-H2O solution by cooling it from below with a constant-temperature surface ranging from -31.5 C to +11.9 C. The NH4Cl concentration was 26 percent in all solutions, with a liquidus temperature of 15 C. It was found that finger convection occurred in the fluid region just above the mushy layer in all experiments. Plume convection with associated chimneys in the mush occurred in experiments with bottom temperatures as high as +11.0 C. However, when the bottom temperature was raised to +11.9 C, no plume convection was observed, although finger convection continued as usual. A method has been devised to determine the porosity of the mush by computed tomography. Using the mean value of the porosity across the mush layer and the permeability calculated by the Kozeny-Carman relationship, the critical solute Rayleigh number across the mush layer for onset of plume convection was estimated to be between 200 and 250.

Chen, C. F.↗
NASA NTRS2008

Effect of Stepwise Pressure Change on Porosity Evolution during Directional Solidification in Small Cylindrical Channels

Controlled directional solidification experiments were performed in capillary channels, using nitrogen-saturated succinonitrile, to examine the effect of an in-situ stepwise processing pressure increase on an isolated pore evolution. Two experiments were performed using different processing pressure input profiles. The results indicate that a processing pressure increase has a transient effect on pore growth geometry characterized by an initial phase of decreasing pore diameter, followed by a recovery phase of increasing pore diameter. The experimental results also show that processing pressure can be used as a control parameter to either increase or terminate porosity formation. A theoretical model is introduced which indicates that the pore formation process is limited by the diffusion of solute-gas through the melt, and that the observed response toa pressure increase is attributed to the re-equilibration of solute concentration in the melt associated with the increased melt pressure.

Grugel, R.N.↗
NASA NTRS1982

Influence of gravity driven convection on the directional solidification of Bi/MnBi eutectic composites

The role of gravity on Bridgman-Stockharger directional solidification of eutectic Bi/MnBi has been studied in reduced gravity aboard NASA sounding rocket SPAR flight experiments and contrasted with normal gravity investigations. The directional solidification of eutectic Bi/MnBi results in a low volume fraction, faceted/nonfaceted aligned rod eutectic whose MnBi rod size, interrod spacing, thermal and magnetic properties are sensitive functions of solidification processing conditions. The morphology of the low-gravity samples showed striking differences compared with identically processed, normal gravity samples grown in the same apparatus. The MnBi rod diameter and interrod spacing distributions were significantly smaller, approximately 50 percent, for the low gravity samples compared with identically processed one gravity samples. Accompanying the smaller MnBi rod diameters observed in the flight samples, was an increase in permanent magnet properties which reached greater than 97 percent of the theoretical maximum. Gravitationally induced thermal instabilities in one-gravity which result in irregular interface movement and associated difficulty of the faceted MnBi phase to branch are suggested to explain the morphological differences between one and low gravity solidification.

Pirich, R. G.↗
NASA NTRS1987

Directional Solidification of Nodular Cast Iron

Cerium enhances formation of graphite nodules. Preliminary experiments in directional solidification of cast iron shows quantitative correlation of graphite microstructure with growth rate and thermal gradient, with sufficient spheroidizing element to form spheroidal graphite under proper thermal conditions. Experimental approach enables use of directional solidification to study solidification of spheriodal-graphite cast iron in low gravity. Possible to form new structural materials from nodular cast iron.

Curreri, P. A.↗
NASA NTRS1999

Novel Directional Solidification Processing of Hypermonotectic Alloys

Gravity driven separation precludes uniform microstructural development during controlled directional solidification (DS) processing of hypermonotectic alloys. It is well established that liquid/liquid suspensions, in which the respective components are immiscible and have significant density differences, can be established and maintained by utilizing ultrasound. A historical introduction to this work is presented with the intent of establishing the basis for applying the phenomena to promote microstructural uniformity during controlled directional solidification processing of immiscible mixtures. Experimental work based on transparent organics, as well as salt systems, will be presented in view of the processing parameters.

Grugel, Richard N.↗
NASA NTRS1987

Directional solidification in an imperfect furnace

The upward directional solidification of a binary alloy in which the rejected solute is more dense than the solvent is considered. The system is stably stratified both thermally and solutally. If heat is lost through the sidewalls, horizontal thermal gradients drive a steady double-diffusive convection. Solidification cells with small aspect ratios (width/length) A are considered, and asymptotic solutions to the steady double-diffusive system are obtained as A tends to 0 under the assumption heat losses are also small. When the thermal Grashof number is large, buoyancy boundary layers are at the sidewalls. The shape of the crystal-melt interface is determined by the coupled effects of local thermodynamic equilibrium, diffusion and convection.

Brattkus, K.↗
NASA NTRS1996

Development Of A Magnetic Directional-Solidification Furnace

Report describes development of directional-solidification furnace in which axial magnetic field is imposed by surrounding ring permanent magnets and/or electromagnets and pole pieces. Furnace provides controlled axial temperature gradients in multiple zones, through which ampoule containing sample of material to be solidified is translated at controlled speed by low-vibration, lead-screw, stepping-motor-driven mechanism. Intended for use in low-gravity (spaceflight) experiments on melt growth of high-purity semiconductor crystals.

Aldrich, Bill R.↗
NASA NTRS1991

Modelling directional solidification

The long range goal of this program is to develop an improved understanding of phenomena of importance to directional solidification and to enable explanation and prediction of differences in behavior between solidification on Earth and in space. Current emphasis is on determining the influence of perturbations on directional solidification.

Wilcox, William R.↗
NASA NTRS1992

Modelling Directional Solidification

The long range goal of this program has been to develop an improved understanding of phenomena of importance to directional solidification, in order to enable explanation and prediction of differences in behavior between solidification on Earth and in space. Current emphasis is on determining the influence of perturbations on directional solidification.

Wilcox, William R.↗
NASA NTRS2001

Toward Understanding Pore Formation and Mobility During Controlled Directional Solidification in a Microgravity Environment Investigation (PFMI)

Porosity in the form of "bubbles and pipes" can occur during controlled directional solidification processing of metal alloys. It is detrimental to material properties and precludes obtaining meaningful scientific results. On Earth, density differences allow an initiated bubble can rise through the liquid and "pop" at the surface resulting in a sound casting. This is not likely to occur in a microgravity environment and, unfortunately, a number of experiments conducted in microgravity have suffered from porosity effects. The current investigation is a systematic effort towards understanding porosity formation and mobility during controlled directional solidification in a microgravity environment. This will be investigated by utilizing a transparent material, succinonitrile (SCN), in conjunction with a translating temperature gradient stage so that direct observation and recording of pore generation and mobility can be made. The talk will cover the porosity problem, the details of the proposed experiments and the experimental hardware, and the expectations from the microgravity experiments.

Grugel, R. N.↗
NASA NTRS2002

Minimizing Segregation During the Controlled Directional Solidification of Dendritic Alloys Publication: Metallurgical and Materials Transactions

Gravity-driven thermosolutal convection that arises during controlled directional solidification (DS) of dendritic alloys promotes detrimental macro-segregation (e.g. freckles and steepling) in products such as turbine blades. Considerable time and effort has been spent to experimentally and theoretically investigate this phenomena; although our knowledge has advanced to the point where convection can be modeled and accurately compared to experimental results, little has been done to minimize its onset and deleterious effects. The experimental work demonstrates that segregation can be. minimized and microstructural uniformity promoted when a slow axial rotation is applied to the sample crucible during controlled directional solidification processing. Numerical modeling utilizing continuation and bifurcation methods have been employed to develop accurate physical and mathematical models with the intent of identifying and optimizing processing parameters.

Grugel, R. N.↗
NASA NTRS2005

Structures Self-Assembled Through Directional Solidification

Nanotechnology has created a demand for new fabrication methods with an emphasis on simple, low-cost techniques. Directional solidification of eutectics (DSE) is an unconventional approach in comparison to low-temperature biomimetic approaches. A technical challenge for DSE is producing microstructural architectures on the nanometer scale. In both processes, the driving force is the minimization of Gibb's free energy. Selfassembly by biomimetic approaches depends on weak interaction forces between organic molecules to define the architectural structure. The architectural structure for solidification depends on strong chemical bonding between atoms. Constituents partition into atomic-level arrangements at the liquid-solid interface to form polyphase structures, and this atomic-level arrangement at the liquid-solid interface is controlled by atomic diffusion and total undercooling due to composition (diffusion), kinetics, and curvature of the boundary phases. Judicious selection of the materials system and control of the total undercooling are the keys to producing structures on the nanometer scale. The silicon-titanium silicide (Si-TiSi2) eutectic forms a rod structure under isothermal cooling conditions. At the NASA Glenn Research Center, directional solidification was employed along with a thermal gradient to promote uniform rods oriented with the thermal gradient. The preceding photomicrograph shows the typical transverse microstructure of a solidified Si-TiSi2 eutectic composition. The dark and light gray regions are Si and TiSi2, respectively. Preferred rod orientation along the thermal gradient was poor. The ordered TiSi2 rods have a narrow distribution in diameter of 2 to 3 m, as shown. The rod diameter showed a weak dependence on process conditions. Anisotropic etch behavior between different phases provides the opportunity to fabricate structures with high aspect ratios. The photomicrographs show the resulting microstructure after a wet chemical etch and a dry plasma etch. The wet chemical etches the silicon away, exposing the TiSi2 rods, whereas plasma etching preferentially etches the Si-TiSi2 interface to form a crater. The porous architectures are applicable to fabricating microdevices or creating templates for part fabrication. The porous rod structure can serve as a platform for fabricating microplasma devices for propulsion or microheat exchangers and for fabricating microfilters for miniatured chemical reactors. Although more work is required, self-assembly from DSE can have a role in microdevice fabrication.

Dynys, Frederick W.↗
NASA NTRS1986

Directional solidification and characterization of near eutectic Sm2CO17/Co alloys

The effects of directional solidification processing on the microstructural, compositional, and magnetic properties of near eutectic Co-Sm alloys (about 9 at. pct Sm) have been studied. Initial investigations have been performed at modest thermal gradients in the liquid, G(L) less than 60 C/cm and over a range of furnace (solidification) velocities, V = 0.8 45.4 cm/h. The primary dendrite spacing for near eutectic Sm2Co17/Co scaled with 1/sq rt V and varied from about 50 microns for V greater than or equal to 20 cm/h to hundreds of microns for V less than 10 cm/h, while the rod eutectic diameter and interrod spacing were an order of magnitude smaller. For both dendritic and cooperative growth, the associated permanent magnet properties were rather poor, e.g., remanence less than 4 kG and coercive force less than 1 kOe for the smallest dendrite and rod diameter dimensions encountered, although the magnetic hardness for the rod eutetic was larger than for the dendritic microstructure. Magnetization as a function of sample orientation indicated that the easy axis of magnetization was primarily along the direction of solidification for both ferromagnetic phases.

Pirich, Ronald G.↗
NASA NTRS1987

Directional solidification of Bi-Mn alloys using an applied magnetic field

Off-eutectic compositions of Bi-Mn were directionally solidified in applied transverse magnetic fields up to 3 kG, to determine the effects on thermal and solutal convection. Plane front directional solidification of eutectic and near-eutectic Bi-Mn results in a two-phase rodlike morphology consisting of ferromagnetic MnBi rods in a Bi solid solution matrix. Compositions of either side of the eutectic were studied in growth orientations vertically up and down. Temperature gradient was monitored during growth by means of an in-situ thermocouple. For Bi-rich compositions, the magnetic field appeared to increase mixing as determined from thermal, morphological, chemical, and magnetic analyses. For Mn-rich compositions, morphological and chemical analyses suggest some reduction in mixing due to application of the magnetic force. The capability for carrying out directional solidification of Bi-Mn in high longitudinal magnetic fields was established.

Decarlo, J. L.↗