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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Studies of directionally solidified eutectic Bi/MnBi at low growth velocities

The (lambda-squared)(V) deviation for diffusion-only rod eutectic growth, where lambda is the interrod spacing and V is the growth velocity, was studied at growth velocities less than 5 cm/h in directionally solidified eutectic Bi-Mn (Bi/MnBi). At lower growth velocities, (V less than 0.5 cm/h) morphological instability occurred which resulted in nonaligned, irregularly dispersed MnBi fibers. The (lambda-squared)(V) relation was experimentally determined over a range of growth velocities between 0.1 and 50 cm/h, thermal gradients in the liquid at the liquid-solid interface that varied from 40 to 120 C/cm and solidification orientation with respect to the direction of gravity. Naturally induced, convective instabilities are suggested as a possible growth velocity limit for cooperative growth in the Bi-Mn and related alloy systems.

Pirich, R. G.↗
NASA NTRS2003

Pore Formation and Mobility Investigation (PPMI): Description and Initial Analysis of Experiments Conducted aboard the International Space Station

Flow visualization experiments during the controlled directional melt back and re-solidification of succinonitrile (SCN) and SCN-water mixtures were conducted using the Pore Formation and Mobility Investigation (PFMI) apparatus in the glovebox facility (GBX) aboard the International Space Station. The study samples were initially 'cast' on earth under 450 millibar of nitrogen into 1 cm ID glass sample tubes approximately 30 cm in length, containing 6 in situ thermocouples. During the Space experiments, the processing parameters and flow visualization settings are remotely monitored and manipulated from the ground Telescience Center (TSC). The ground solidified sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. Bubbles of different sizes are seen to initiate at the melt interface and, upon release from the melting solid, translate at different speeds in the temperature field ahead of them before coming to rest. Over a period of time these bubbles dissolve into the melt. The gas-laden liquid is then directionally solidified in a controlled manner, generally starting at a rate of 1 micron /sec. Observation and preliminary analysis of bubble formation and mobility in pure SCN samples during melt back and the subsequent structure resulting during gas generation upon re-solidification are presented and discussed.

Grugel, R. N.↗
NASA NTRS2002

Pore Formation and Mobility Investigation (PFMI): Description and Initial Analysis of Experiments Conducted aboard the International Space Station

Flow visualization experiments during the controlled directional melt back and re-solidification of succinonitrile (SCN) and SCN-water mixtures were conducted using the Pore Formation and Mobility Investigation (PFMI) apparatus in the glovebox facility (GBX) aboard the International Space Station. The study samples were initially "cast" on earth under 450 millibar of nitrogen into 1 cm ID glass sample tubes approximately 30 cm in length, containing 6 in situ thermocouples. During the Space experiments, the processing parameters and flow visualization settings are remotely monitored and manipulated from the ground Telescience Center (TSC). The ground solidified sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. Bubbles of different sizes are seen to initiate at the melt interface and, upon release from the melting solid, translate at different speeds in the temperature field ahead of them before coming to rest. Over a period of time these bubbles dissolve into the melt. The gas-laden liquid is then directionally solidified in a controlled manner, generally starting at a rate of 1 micron /sec. Observation and preliminary analysis of bubble formation and mobility in pure SCN samples during melt back and the subsequent structure resulting during gas generation upon re-solidification are presented and discussed.

Grugel, R. N.↗
NASA NTRS1991

Estimation of the engineering elastic constants of a directionally solidified superalloy for finite element structural analysis

The temperature-dependent engineering elastic constants of a directionally solidified nickel-base superalloy were estimated from the single-crystal elastic constants of nickel and MAR-MOO2 superalloy by using Wells' method. In this method, the directionally solidified (columnar-grained) nickel-base superalloy was modeled as a transversely isotropic material, and the five independent elastic constants of the transversely isotropic material were determined from the three independent elastic constants of a cubic single crystal. Solidification for both the single crystals and the directionally solidified superalloy was assumed to be along the (001) direction. Temperature-dependent Young's moduli in longitudinal and transverse directions, shear moduli, and Poisson's ratios were tabulated for the directionally solidified nickel-base superalloy. These engineering elastic constants could be used as input for performing finite element structural analysis of directionally solidified turbine engine components.

Abdul-Aziz, Ali↗
NASA NTRS2023

Numerical Study of Solidification Crack Susceptibility in Novel Refractory Alloy Systems

Calculation of Phase Diagrams (CALPHAD) -based solidification computa­tions, such as Scheil or equilibrium computations, have been utilized to propose crack solidification susceptibility indices (CSSIs) of cracking. These CSSIs have been proposed in order to predict the cracking susceptibility of an alloy in the solidification range, as a function of its solidification frac­tion and as dependent upon its wt.% elemental composition through the CALPHAD computation & via comparative methods between one composition & the next. Recently Kou at al. have proposed a novel CSSI where the gradient of the e.x. Scheil solidification curve is obtained in the critical solidification cracking region of greater than 0.95 fraction of solid. Therefore, a direct Temperature dependent metric is now available for the prediction, and presumably the control, of solidification cracking. In this TM, the researchers apply this Kou gradient method to refractory alloys for the first time & discuss justification for the approach via Spearman rank correlation with Varestraint cracking test data as well as by comparisons with Thermocalc based vulnerability time CSSI calculations. A Python Pycalphad module example of the approach is provided & can be utilized as an open-source resource that utilizes also open-source available thermodynamical databases, making the CSSI quantitative aspect of ICME more available and freely available to practitioners.

ICME integrated computational materials engineerin↗
NASA NTRS1975

Thermal fatigue and oxidation data on TAZ-8A, MAR-M 200, and Udimet 700 superalloys

The fluidized bed technique was used to determine the relative thermal fatigue and oxidation resistance of three superalloys: TAZ-8A, Mar-M 200, and Udimet 700. The alloys TAZ-8A and MAR-M 200 were also tested in the directionally-solidified form. For the 13 combinations of composition, solidification method, surface protection, and specimen geometry, the cycles to cracking varied from 1250 to 15,000. The alloy/coating having the best resistance to thermal fatigue cracking was coated directionally-solidified NASA TAZ-8A. This combination also had excellent oxidation resistance.

Howes, M. A. H.↗
DOE OSTI2025

Isothermal solidification for high-entropy alloy synthesis

Kinetically trapping the high-temperature states through rapid cooling solidification is widely used for the synthesis of high-entropy alloys (HEAs), especially those with intrinsically immiscible elemental combinations. However, strategies need to be developed to overcome the fundamental limitations of rapid cooling solidification in controlling the crystallinity, structure and morphology of HEAs. Here, in this study, we introduce an isothermal solidification strategy for the synthesis of HEAs by rapidly altering the metal alloy composition through liquid–liquid interface reactions at low temperatures, for example, from 25 °C to 80 °C. We use gallium (Ga)-based metal as the sacrificial reagent and mixing medium. By directing the reactions to the interfaces between the Ga-based liquid metal and an aqueous metal ion solution, the foreign metal ions can be reduced at the interfaces and incorporated into the liquid metal quickly. HEAs with various crystallinity (single crystal, mesocrystal, polycrystal and amorphous), morphology (zero, two and three dimensions) and compositions can be achieved through the isothermal solidification. Ga can be completely consumed, resulting in Ga-free HEAs. If desired, Ga can be one of the metal elements in the final products. In situ liquid phase transmission electron microscopy (TEM) studies and theoretical analysis show the isothermal solidification mechanisms. Our direct observations show the enhanced mixing of liquid metal elements and the solidification process with fluctuating nucleation dynamics. The isothermal solidification marks a powerful strategy for HEA synthesis through an unexplored pathway of kinetically trapping the high-entropy states.

Zhang, Qiubo [Lawrence Berkeley National Laborator↗
NASA NTRS1983

Effect of variable thermal conductivity on isotherms in Bridgman growth

A change in thermal conductivity associated with melting or solidification can have a profound influence on the isotherms near the solidification interface if the material is being directionally solidified in an ampoule whose walls carry a substantial portion of the heat. This analysis was prompted by a recent discovery that the thermal conductivity of Hg(1-x)CD(x)Te increased dramatically as the material is heated above the solidus curve. An illustrative example is shown in which the sample is approximated as an infinite cylinder with constant but diffferent thermal properties in the solid and melt. The boundary conditions are fixed on the surface by a conductive ampoule in a two-zone Bridgman furnace with an adiabatic region separating the two zones. The effect of the adiabatic zone in this case is to intensify the curvature of the interface rather than to lessen it.

Naumann, R. J.↗
NASA NTRS1996

Producing Foils From Direct Cast Titanium Alloy Strip

This research was undertaken to demonstrate the feasibility of producing high-quality, thin-gage, titanium foil from direct cast titanium strip. Melt Overflow Rapid Solidification Technology (MORST) was used to cast several different titanium alloys into 500 microns thick strip, 10 cm wide and up to 3 m long. The strip was then either ground, hot pack rolled or cold rolled, as appropriate, into foil. Gamma titanium aluminide (TiAl) was cast and ground to approximately 100 microns thick foil and alpha-2 titanium aluminide (Ti3AI) was cast and hot pack rolled to approximately 70 microns thick foil. CP Ti, Ti6Al2Sn4Zr2Mo, and Ti22AI23Nb (Orthorhombic), were successfully cast and cold-rolled into good quality foil (less than 125 microns thick). The foils were generally fully dense with smooth surfaces, had fine, uniform microstructures, and demonstrated mechanical properties equivalent to conventionally produced titanium. By eliminating many manufacturing steps, this technology has the potential to produce thin gage, titanium foil with good engineering properties at significantly reduced cost relative to conventional ingot metallurgy processing.

Stuart, T. A.↗
NASA NTRS2004

Materials Processing in Space: Model Experiments aboard the International Space Station

Direct observation of fluid flow, bubble movement and solidification during controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus in the glovebox facility (GBX) on board the ISS. Experimental processing parameters of temperature gradient and translation speed, as well as camera settings, were remotely monitored and manipulated from the ground Telescience Center (TSC) at the Marshall Space Flight Center. Real time visualization of the controlled directional melt back and resolidification reveals a number of microgravity dependent phenomena otherwise masked by Earth s gravity. These and some initial analysis of the observed events is presented.

Grugel, Richard↗
NASA NTRS1984

NBS (National Bureau of Standards): Materials measurements

Work in support of NASA's Microgravity Science and Applications Program is described. The results of the following three tasks are given in detail: (1) surface tensions and their variations with temperature and impurities; (2) convection during unidirectional solidification; and (3) measurement of high temperature thermophysical properties. Tasks 1 and 2 were directed toward determining how the reduced gravity obtained in space flight can affect convection and solidification processes. Emphasis in task 3 was on development of levitation and containerless processing techniques which can be applied in space flight to provide thermodynamic measurements of reactive materials.

Manning, J. R.↗
NASA NTRS1994

Reply

Treiman (this issue) argues that the melting temperature of carbonatite used by Gregg and Greeley (1993) is too low, and that values presented for other thermophysical properties for carbonatite lava are more appropriate for carbonatite rock. With the exception of the mechanical solidification temperature, values presented by Gregg and Greeley (1993) were taken directly, or calculated, from values presented within the works by Dawson et al. (1990) and Keller and Krafft (1990). Because a mechanical solidification temperature for carbonatite lavas was not presented in those works, we estimated one based on extrusion temperature, Venusian surface pressure, and the temperatures measured in cooling carbonatite lava lakes. We have reexamined values shown for properties of carbonatite lavas used by Gregg and Greeley (1993), and concur that Treiman's arguments (Treiman, this issue) are valid. Here, we present results of analyses described in Gregg and Greeley 1993, using values for the properties of carbonatite lavas obtained from Treiman and Schedl (1983) and Norton and Pinkerton (1990).

Gregg, Tracy K. P.↗
NASA NTRS1984

The solidification of monotectic alloys - Microstructures and phase spacings

The microstructures of directionally grown monotectic alloys in metallic and organic systems fall into two categories those which can form aligned fibrous composite structures with even phase spacings and fiber sections, and those in which the phase distribution is coarser and less regular. This division appears to relate to the form of the phase diagram and has been rationalized by Cahn (1977, 1979) in terms of the relative surface energies between solid and two liquids to give steady state or nonsteady state profiles. The transition in growth behavior occurs when the ratio of the monotectic temperature to that of the upper consolute temperature is approximately 0.9. Differences in phase spacings between a range of monotectic and eutectic systems are discussed in terms of the expected growth interface shapes and the factors which will influence them.

Grugel, R. N.↗
NASA NTRS2001

Shuttle Flight Experiment on USMP-4: In Situ Monitoring of Crystal Growth Using MEPHISTO

This reports on the MEPHISTO-4 experiment on the Space Shuttle Columbia, STS-87, November 19-December 5, 1997. Involved were NASA; the University of Florida at Gainesville; groups from France that developed and built the furnace; the National Institute of Standards and Technology; The University of New South Wales, Australia; and Purdue University. This was a solidification study in which three long rods of Bismuth- 1 at.% Tin were directionally solidified. The goals were to solidify in an environment free of natural convection; to determine the relationship among solidification growth velocity, growth mode, and temperature; and determine the diffusivity of Sn in Bi. The flight samples grew with a planar solid/liquid interface at velocities less than 3.4 gm/s, and cellular growth was present at velocities greater than 6.7 um/s; grain orientation influenced the planar to cellular transition. The temperature gradient in the liquid was 204 K/cm. The s/l interface was flat with slight concavity. Diffusion-dominated conditions were present during MEPHISTO-4. The Seebeck technique was used to determine the s/I interface temperature during growth, however, to date, analysis of the Seebeck results has not yielded a reliable measurement of the interface temperature. The partition coefficient for Bi alloyed with Sn was measured, k = 0.029.

Abbaschian, Reza↗
NASA NTRS1991

Solidification processing superalloys in an electric field

The phase morphology of a given superalloy's microstructure is established during solidification. Solidification-processing in an applied electric field is a technique currently undergoing experimental characterization at NASA-Marshall. The method is predicated on the simplest model of a metallic solid, in which ions are arranged in basic space lattices that are permeated by an 'electron gas' whose valence electrons are free to move in the solid. When in a superheated liquid state, the metal is seen as a dense 'cold plasma' of electrons and ions. The application of an electric field during solidification establishes a steady, continuous current flow; the direction of propagation of the plasma waves coincides with the direction of the electric field. Such an alignment introduces an ordered arrangement of the electric vectors and introduces an additional degree of order in an already highly ordered alloy.

Ahmed, Shaffiq↗
NASA NTRS2000

Onset of Convection Due to Surface Tension Variations in Multicomponent and Binary Fluid Layers

Under certain conditions, such as in thin liquid films or microgravity, surface tension variations along a free surface can induce convection. Convection onset due to surface tension variation is important to many terrestrial technological processes in addition to microgravity materials processing applications. Examples include coating, drying crystallization, solidification, liquid surface contamination, and containerless processing. In double-diffusive and multicomponent systems, the spatial variations of surface tension are associated with two or more stratifying agencies, respectively. For example, both temperature and species (concentration) gradients are associated with convection in the solidification of binary alloys or salt ponds. The direction of the two (or more) gradients has a profound effect on the nature of the flow at or slightly beyond the onset of convection. Our recent work at the NASA Lewis Research Center focused on characterizing surface-tension-induced onset of convection, often referred to as Marangoni-Benard convection. Exact solutions for the stationary neutral stability of multicomponent fluid layers with interfacial deformation were derived. These solutions also permit the computation of a boundary curve that separates the long and finite wavelength instabilities. Computing points along this boundary using the exact solution (when possible) is more efficient than the typical numerical approaches, such as finite difference or spectral methods. Above the curve, a long wavelength instability was predicted, suggesting that convection would occur principally through one large flow cell in the layer, whereas below the curve, finite wavelength instabilities occur which suggest multiple finite-sized circulation cells. For many common liquids with layer depths greater than 100 mm, finite wave instability is predicted under terrestrial conditions; however, with little exception, long wavelength instability is predicted in microgravity for the identical fluid systems.

Skarda, J. Raymond Lee↗
NASA NTRS1980

SPAR and ASTP studies of plane-front solidification and magnetic properties of Bi/MnBi

Eutectic and off-eutectic Bi/MnBi compositions have been directionally solidified parallel, anti-parallel and perpendicular to the gravity vector in a one-g environment and in low-gravity during the ASTP flight. MnBi rod diameter and interparticle spacing distributions are similar for all gravity vector orientations when grown at high solidification rates in one-g. Previously reported ASTP results are explained by the existence of a metastable magnetic phase and off-eutectic solidification models.

Pirich, R. G.↗
DOE OSTI2026

Enabling On-Demand Aerospace Component Manufacturing: Topology Optimization of GE Engine Bracket and Fabrication Using Metal FFF

Additive Manufacturing (AM) offers advantages over conventional manufacturing processes, particularly by reducing the number of parts produced through multistage combined technologies, but these often result in low manufacturing yields or require post-processing. AM facilitates the production of complex geometries with fine features, overhangs, and lattice structures. For instance, Laser Powder Bed Fusion (LPBF) technology enables the fabrication of intricate parts that can be easily post-processed by removing residual powder. Laser powder bed AM technologies are widely discussed in the literature due to their design freedom in creating complex geometries, with and without the need for support generation. However, rapid solidification due to a thermal gradient in the build direction, which leads to the formation of columnar grains and warpage, is one of the challenges. To address this challenge, we propose layer-by-layer metal FFF technology, followed by the debinding and sintering process, as an alternative to powder- and laser-based approaches. Furthermore, design for additive manufacturing (DfAM) principles are discussed to minimize the need for support generation and enable easy post-processing, thereby improving surface finish to meet high tolerances in fabricating components for aerospace and healthcare applications.

Singh, Abhishek [University of Michigan, Ann Arbor↗