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At least 73 records · Page 4

Channel formation in Pb-Sn, Pb-Sb, and Pb-Sn-Sb alloy ingots and comparison with the system NH4Cl-H2O

The formation of segregation channels during the unidirectional solidification of base chilled ingots has been studied as a function of composition in binary Pb-Sn and Pb-Sb and ternary Pb-Sn-Sb alloys. The patterns of channel distribution were characterized in the binary and ternary systems and are described as functions of temperature gradients, growth rates, dendrite spacings, and interdendritic permeabilities. Channels appear to nucleate at random across a dendritic front and subsequently to interact as they propagate, decreasing in density across the front. Assuming that the interdendritic spacing is the characteristic distance for a liquid perturbation, yields critical effective Rayleigh numbers which lie within a factor of x 40 for both metallic and aqueous systems. This correlation is close, considering the sensitivity to any assumed dimension and the range of material properties involved, and is taken to support a model for channel nucleation occurring close to the dendritic growth front.

Hellawell, A.↗

Casting And Solidification Technology (CAST): Directional solidification phenomena in a metal model at reduced gravity

The Casting and Solidification Technology (CAST) experiment will study the phenomena that occur during directional solidification of an alloy, e.g., constitutional supercooling, freckling, and dendrite coarsening. The reduced gravity environment of space will permit the individual phenomena to be examined with minimum complication from buoyancy driven flows.

Mccay, M. H.↗

Mechanism and models for zinc metal morphology in alkaline media

Based on experimental observations, a mechanism is presented to explain existence of the different morphologies of electrodeposited zinc in alkaline solution. The high current density dendrites appear to be due to more rapid growth on the nonbasal crystallographic planes than on the basal plane. The low current density moss apparently results from dissolution from the nonbasal planes at low cathodic voltages. Electrochemical models were sought which would produce such a phenomenon. The fundamental plating mechanism alone accounts only for different rates on different planes, not for zinc dissolution from a plane in the cathodic region. Fourteen models were explored; two models were in accord with the proposed mechanism. One involves rapid disproportionation of the zinc +1 species on the nonbasal planes. The other involves a redox reaction (corrosion) between the zinc-zincate and hydrogen-water systems.

May, C. E.↗

Solidification of undercooled metals

The present investigation is concerned with the subject of undercooling (i.e., supercooling) in the case of metal alloys, taking into account the effects of undercooling on microstructure and microsegregation in alloys which solidify in a crystalline manner. Techniques for obtaining a large degree of undercooling are discussed. These techniques make it possible to eliminate heterogeneous nucleants from the melt and to remove container nucleation effects. The nucleation behavior of small metal droplets is considered along with the formation of a dispersion of fine droplets in a suitable inert medium, the mixing of fine metal powders with glass powder, and the levitation melting technique. Attention is given to solidification with rapid interface velocity, aspects of dendritic morphology, and thermal measurements during solidification of undercooled droplets.

Flemings, M. C.↗

Shock Effects in the Metal-rich Chondrites QUE 94411, Hammadah al Hamra 237 and Bencubbin

We have studied the metal-rich chondrites QUE94411 (QUE), Hammadah al Hamra 237 (HH237) and Bencubbin with an emphasis on the petrographical and mineralogical effects of the shock processing that these meteorite assemblages have undergone. Iron-nickel metal and chondrule silicates are the main components in these meteorites. These high-temperature components are held together by shock melts consisting of droplets of dendritically intergrown FeNi metal/sulfide embedded in ferrous silicate glass. The silicate glass component of the shock melt is substantially more FeO-rich (FeO: 30 to 40 wt%) than the prevailing chondrule silicates (FeO less than 5 wt%). Fine-grained matrix material, which is a major component in most other chondritic assemblages, is extremely scarce in QUE4411 and HH237; it has not been observed in Bencubbin. This material occurs as rare, hydrated, and fine-grained matrix lumps with major and minor element abundances roughly similar to the ferrous silicate shock melts (and CI). We infer that hydrated, fine-grained material, compositionally similar to these matrix lumps, was originally present between the FeNi metal grains and chondrules, but was preferentially heated by the shock wave and melted. Other shock-related features in QUE94411, HH237, and Bencubbin include a distinct alignment and occasionally strong plastic deformation of metal and chondrule fragments. However, the existence of chemically zoned and metastable FeNi metal condensates condensates in direct contact with shock melts indicates that the shock did not substantially increase the average temperature of the aggregate. TEM analyses of the FeNi metal droplets embedded in the shock melts show martensitic crystal structures, indicating rapid cooling, essentially quenching, of the shock melts. These findings indicate that the preshock temperature of the assemblage was low. Because porphyritic olivine-pyroxene chondrules are absent in QUE94411, HH237, and Bencubbin, it is difficult to determine the precise shock stage of these meteorites, but the shock was probably relatively light (S2- S3; 5-20 GPa) consistent with a bulk temperature increase of the assemblages of less than 200 C. The higher pressures within this range (i.e. 15-20 GPa) are consistent with the findings of shock produced diamonds in Bencubbin. The many mineralogical, petrological and isotopic (e.g. O and N) similarities between Bencubbin, Weatherford, Gujba and QUE/HH237 have been used to argue for a common origin of these meteorites on a single asteroidal parent body. The findings of this study, which indicate similar shock processing, lend support to this view.

Meibom, A.↗

A Module Experimental Process System Development Unit (MEPSDU)

Design work for a photovoltaic module, fabricated using single crystal silicon dendritic web sheet material, resulted in the identification of surface treatment to the module glass superstrate which improved module efficiencies. A final solar module environmental test, a simulated hailstone impact test, was conducted on full size module superstrates to verify that the module's tempered glass superstrate can withstand specified hailstone impacts near the corners and edges of the module. Process sequence design work on the metallization process selective, liquid dopant investigation, dry processing, and antireflective/photoresist application technique tasks, and optimum thickness for Ti/Pd are discussed. A noncontact cleaning method for raw web cleaning was identified and antireflective and photoresist coatings for the dendritic webs were selected. The design of a cell string conveyor, an interconnect feed system, rolling ultrasonic spot bonding heat, and the identification of the optimal commercially available programmable control system are also discussed. An economic analysis to assess cost goals of the process sequence is also given.

Source record↗

Solidification processing of monotectic alloy matrix composites

Directionally solidified aluminum-indium alloys of the monotectic composition were found to form an in situ rod composite which obeys a lambda exp 2 R = constant relation. The experimental data shows good agreement with previously reported results. A theoretical boundary between cellular and dendritic growth conditions was derived and compared with experiments. The unique wetting characteristics of the monotectic alloys can be utilized to tailor the interface structure in metal matrix composites. Metal matrix composites with monotectic and hypermonotectic Al-In matrices were made by pressure infiltration, remelted and directionally solidified to observe the wetting characteristics of the alloys as well as the effect on structure of solidification in the constrained field of the fiber interstices. Models for monotectic growth are modified to take into account solidification in these constrained fields.

Frier, Nancy L.↗

Effects of Melt Convection and Solid Transport on Macrosegregation and Grain Structure in Equiaxed Al-Cu Alloys

Macrosegregation in metal casting can be caused by thermal and solutal melt convection, and the transport of unattached solid crystals resulting from nucleation in the bulk liquid or dendrite fragmentation. To develop a comprehensive numerical model for the casting of alloys, an experimental study has been conducted to generate benchmark data with which such a solidification model could be tested. The objectives were: (1) experimentally study the effects of solid transport and thermosolutal convection on macrosegregation and grain size; and (2) provide a complete set of boundary conditions temperature data, segregation data, and grain size data - to validate numerical models. Through the control of end cooling and side wall heating, radial temperature gradients in the sample and furnace were minimized. Thus the vertical crucible wall was adiabatic. Samples at room temperature were 24 cc and 95 mm long. The alloys used were Al-1 wt. pct. Cu, and Al- 10 wt. pct. Cu; the starting point for solidification was isothermal at 710 and 685 C respectively. To induce an equiaxed structure various amounts of the grain refiner TiB2 were added. Samples were either cooled from the top, or the bottom. Several trends in the data stand out. In attempting to model these experiments, concentrating on these trends or differences may be beneficial.

Rerko, Rodney S.↗

Homogeneous eutectic of Pb-Sb

Dendrite free eutectic mixture of Pb-Sb is expected to be superelastic material that can be used in formation of shaped charge liners for industrial explosive metal-forming processes and other applications.

Winter, J. M., Jr.↗

Chemical fractionations in group IIIAB iron meteorites - Origin by dendritic crystallization of an asteroidal core

Results of an investigation of the crystallization history of the asteroidal core that produced nearly 200 iron meteorites of group IIIAB are presented. The accuracy of the published distribution of coefficients between solid and liquid metal for seven elements and their dependence on the concentrations of S and P are critically assessed to develop a nonideal fractional crystallization model that reproduces all of the major features of the overall chemical trends in group IIIAB. It is suggested that the apparent distribution coefficient of S was was much higher than its equilibrium value (not greater than 0.01) and that it increased during crystallization. In the present preferred model the apparent distribution coefficient for S increases from 0.6 to 0.8, while the S concentration of the liquid increases from 6 to 13 wt pct. It is inferred that light S-rich liquid accumulates preferentially at the top of the core and in structural traps formed by the advancing solid.

Haack, Henning↗

Lithium Dinitramide as an Additive in Lithium Power Cells

Lithium dinitramide, LiN(NO2)2 has shown promise as an additive to nonaqueous electrolytes in rechargeable and non-rechargeable lithium-ion-based electrochemical power cells. Such non-aqueous electrolytes consist of lithium salts dissolved in mixtures of organic ethers, esters, carbonates, or acetals. The benefits of adding lithium dinitramide (which is also a lithium salt) include lower irreversible loss of capacity on the first charge/discharge cycle, higher cycle life, lower self-discharge, greater flexibility in selection of electrolyte solvents, and greater charge capacity. The need for a suitable electrolyte additive arises as follows: The metallic lithium in the anode of a lithium-ion-based power cell is so highly reactive that in addition to the desired main electrochemical reaction, it engages in side reactions that cause formation of resistive films and dendrites, which degrade performance as quantified in terms of charge capacity, cycle life, shelf life, first-cycle irreversible capacity loss, specific power, and specific energy. The incidence of side reactions can be reduced through the formation of a solid-electrolyte interface (SEI) a thin film that prevents direct contact between the lithium anode material and the electrolyte. Ideally, an SEI should chemically protect the anode and the electrolyte from each other while exhibiting high conductivity for lithium ions and little or no conductivity for electrons. A suitable additive can act as an SEI promoter. Heretofore, most SEI promotion was thought to derive from organic molecules in electrolyte solutions. In contrast, lithium dinitramide is inorganic. Dinitramide compounds are known as oxidizers in rocket-fuel chemistry and until now, were not known as SEI promoters in battery chemistry. Although the exact reason for the improvement afforded by the addition of lithium dinitramide is not clear, it has been hypothesized that lithium dinitramide competes with other electrolyte constituents to react with lithium on the surface of the anode to form a beneficial SEI. Apparently, nitrides and oxides that result from reduction of lithium dinitramide on the anode produce a thin, robust SEI different from the SEIs formed from organic SEI promoters. The SEI formed from lithium dinitramide is more electronically insulating than is the film formed in the presence of an otherwise identical electrolyte that does not include lithium dinitramide. SEI promotion with lithium dinitramide is useful in batteries with metallic lithium and lithium alloy anodes.

Gorkovenko, Alexander A.↗

Migratory gold resistive shorts - Chemical aspects of a failure mechanism

Integrated-circuit devices using the Ti/W/Au metal system are subject to failure mechanisms based on electrolytic corrosion. The migratory gold resistive short (MGRS) failure mode is one example of this mechanism and results in the formation of filamentary or dendritic deposits of gold between adjacent stripes on the IC chip. This reaction requires the presence of a sufficient amount of water, a bias voltage between adjacent stripes, and the activation of the cathodic (-) stripe. Gold ions are transported from anode to cathode through a film of moisture adsorbed on the surface of the chip; halide ions are probably involved in the transfer. Their presence is verified experimentally by X-ray photoelectron spectroscopy. Some of the chemical and electrostatic factors involved in the MGRS mechanism are discussed in this paper, including the questions of a threshold level of moisture and contamination.

Grunthaner, F. J.↗

Effect of Melt Convection and Solid Transport on Macrosegregation and Grain Structure in Equiaxed Al-Cu Alloys

Macrosegregation in metal casting can be caused by thermal and solutal melt convection, and the transport of unattached solid crystals. These free grains can be a result of, for example, nucleation in the bulk liquid or dendrite fragmentation. In an effort to develop a comprehensive numerical model for the casting of alloys, an experimental study has been conducted to generate benchmark data with which such a solidification model could be tested. The specific goal of the experiments was to examine equiaxed solidification in situations where sinking of grains is (and is not) expected. The objectives were: 1) experimentally study the effects of solid transport and thermosolutal convection on macrosegregation and grain size distribution patterns; and 2) provide a complete set of controlled thermal boundary conditions, temperature data, segregation data, and grain size data, to validate numerical codes. The alloys used were Al-1 wt. pct. Cu, and Al-10 wt. pct. Cu with various amounts of the grain refiner TiB2 added. Cylindrical samples were either cooled from the top, or the bottom. Several trends in the data stand out. In attempting to model these experiments, concentrating on experiments that show clear trends or differences is recommended.

Rerko, Rodney S.↗

Theoretical aspects of undercooling, nucleation and growth of metals in space

A mathematical model which can predict solid material properties from known melt properties and solidification environment is being developed to aid in selecting materials systems which could benefit scientifically or commercially from experimentation in space. In its present, preliminary form, the model calculates grain size and dendrite morphology from the undercooling parameter and the parameter which characterizes heterogeneous nucleation. Calculations with the present model are compared to experimental data, and needed improvements in the model are described. Some theoretical problems relating to undercooling and environmentally-induced solute segregation are also discussed.

Miller, R. I.↗

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.↗

An optical study of grain formation: Casting and solidification technology (2-IML-1)

By studying the unidirectional growth of a metal-model material in microgravity, an attempt is made to characterize alloy solidification. Using holograms and supporting temperature measurements obtained during processing in the Fluids Experiment System (FES), the solute and thermal fields associated with the dendrite growth front and extraneous nucleation will be measured and compared to a theoretical (computational) model. Ground based supporting experiments include particle tracking to measure the velocity fields, and optical phase shift techniques (confocal optical signal processing, interferometry, and Schlieren) to study thermal and solutal fields.

Mccay, Mary H.↗

Containerless drop tube solidification and grain refinement of NiAl3

The possibility of undercooling Ni-Al alloys below the liquidus in order to produce a single phase peritectic structure by containerless drop tube solidification was studied. Containerless process is a technique for both high purity contamination free studies as well as for investigating the undercooling and rapid solidification of alloys by suppression of heterogeneous nucleation on container walls. In order to achieve large undercoolings one must avoid heterogeneous nucleation of crystallization. It was shown that the Marshall Space Flight Center drop tubes ae unique facilities for containerless solidification experiments and large undercoolings are possible with some alloys. The original goal of undercooling the liquid metal well below the liquidus to the peritectic temperature during containerless free to form primarily NiAl3 was achieved. The microstructures were interesting from another point of view. The microstructure from small diameter samples is greatly refined. Small dendrite arm spacings such as these could greatly facilitate the annealing and solid state transformation of the alloy to nearly 10% NiAl3 by reducing the distance over which diffusion needs to occur. This could minimize annealing time and might make it economically feasible to produce NiAl3 alloy.

Ethridge, E. C.↗

Project Description and Publications List for UAH CMMR

This research combines a state of the art X-ray Transmission Microscope, XTM, with a specially designed x-ray transparent horizontal Bridgman furnace to image (with resolutions up to 3 micrometers) the solidification of metal alloys in real-time. The objective is to obtain real-time dynamic data to provide direct measure of the solute profile in the liquid, phase coalescence and growth in the liquid, and the detailed interface morphology (e,g., dendrites and cells) during solidification. We are also enhancing the XTM data with precise solid-liquid interfacial temperature and the thermal gradient measurement techniques, and working on the application of this technology to the study of the fundamentals of solidification in microgravity. Over the last several years we have successfully imaged in real-time: interfacial-morphologies, phase growth, coalescence, incorporation of phases into the growing interface, and the solute boundary layer in the liquid at the solid-liquid interface. We have also measured true local growth rates and can evaluate segregation structures in the solid. Interfacial undercoolings are being measured either with a special Seebeck furnace or with micro-thermocouple arrays we are developing. These later techniques are presently being incorporated with the XTM furnace. This last year emphasized the investigation of the solute layer in the melt during solidification. Methods were developed to quantify the solute concentrations using x-ray absorption and to compare to predictions from simulations. In addition, work is being completed on a brass-board portable XTM that incorporates a vertical Bridgman furnace.

Kaukler, William F.↗