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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 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

A Solid Case for Microgravity Processing

Solidification of metals, particularly alloys, is a complicated process. At some sufficiently high temperature, the components comprising an alloy fully mix, producing a single homogeneous liquid. Unfortunately, after this liquid is cast into a mold and allowed to freeze, the resulting solid is usually very inhomogeneous. In most cases the first solid to "freeze out" of the liquid has a composition very close to one of the pure metals. This initially solidifying metal usually comprises microscopic, pine-tree shaped components, collectively referred to as a dendritic array, whose distribution, alignment, and scale directly influence a materials strength and docility. During dendrite growth the adjacent liquid becomes enriched, and consequently, solidifies a much lower temperature and considerably later time. Thus, in the course of solidification, both the solid and the enriched liquid can have compositions (and local temperatures) significantly different from those of the bulk liquid. Different compositions and temperatures imply different densities that, in Earth's gravity, induce motion in the liquid. Such motion promotes formation of a casting that is denser at the bottom and lighter at the top. This condition known as macrosegregation, precludes optimized, uniform material properties.

Grugel, Richard N.↗
DOE OSTI2019

Microstructure and Mechanical Properties of Ni-based Superalloy K418 Produced by the Continuous Unidirectional Solidification Process

Adopting effective strategies to control the solidification structure of Ni-based superalloys is a very interesting subject for metallurgists. Despite the achievement of developing and applying the continuous unidirectional solidification process in simple alloys, the utilization of this process for K418 alloys has been ignored. The microstructure and mechanical properties of a K418 alloy ingot produced by the continuous unidirectional solidification process were investigated. We found that the γ dendrites were typically cross-shaped in the transverse section. The orientation of surviving grains along the casting direction was <001> during competitive growth. The secondary dendrite arm spacing was 32.3 ± 2.5 μm at a cooling rate of 1.75 ± 0.35 °C/s from the surface to the center of the K418 alloy ingot. Due to the higher cooling rate than that of the conventional casting process, a more uniform microstructure and finer γ′ precipitation were obtained in the ingot. Thus, compared with the conventional casting, the tensile strength and the elongation are increased by 8.4 and 21.3%, respectively, at 25 °C. The tensile strength and elongation increased by 15.2 and 49.3%, respectively, at 800 °C. In addition, the fracture surfaces exhibited numerous typical dimples and dendritic fracture characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Controllable Solar Flux Heating for Freeze Recovery in Molten Salt Parabolic Trough Collectors

In molten-salt parabolic trough plants, the melting process is particularly important for freeze recovery of salt that is solidified in a collector loop, should such an event occur. Currently impedance heating is expected for freeze recovery of the collector loops, but this method can be expensive. Here, a lower-cost alternative is proposed to use controllable concentrated solar flux directly from the parabolic mirrors to thaw salt that is frozen in the collector. A computational fluid dynamics model was developed to explore the solidification and melting processes of molten salt in a parabolic trough receiver and to assess the viability of this concept. Results indicate that concentrated solar heating has the potential to melt frozen salt in 5.6 h, compared to that in 8.8 h for a 300 W m –1 impedance heating system. At the same time, controllable solar flux heating introduces nonuniform solar fluxes on the receiver surface, which can induce significant thermal stress on the receiver tube. A preliminary stress analysis indicates that the temperature difference across the receiver tube should be maintained below about 70 °C for heating up to 300 °C at internal pressures ≤10 bar. At these conditions, freeze recovery using solar flux heating will not significantly affect receiver lifetime. These results suggest that controllable solar flux heating could effectively supplement or replace impedance heating in the freeze recovery system. Incorporating this methodology in future parabolic trough concentrating solar power plants is an opportunity for capital and operational cost-savings.

14 SOLAR ENERGY↗
NASA NTRS1981

Materials processing in space: A survey of referred open literature publications

Over 190 reports published in the open literature by workers in the materials processing in space program are listed according to year as well as alphabetically by author. Thirty five reports submitted for publication are also cited. Supported either directly or indirectly by NASA, the research generally pertains to the influence (or lack of influence) of gravity on processes involved in crystal growth, solidification, fluid transport, containerless phenomena, and various separation techniques of interest to the biomedical community. Studies of the possibilities of using the high vacuum in the wake of orbiting vehicles for performing processes involving large heat loads and evolution of gases are also included.

Pentecost, E.↗
NASA NTRS1987

On the role of convective motion during dendrite growth: Experiments under variable gravity, revised

Experiments show the effect of self induced convection on individual dendrite growth in uniformly supercooled samples and solidification of the resulting mush under conditions of high and low g. Convection is visualized by a Schlieren optical system or a Mach Zender interferometer. For ice crystals growing from the vapor in air, a slight reduction in linear growth rate occur under low g. For ice crystals growing from NaCl solution, dendrite tip velocities are unchanged, but subsequent mush solidification is enhanced through drainage channels under higher g. By contrast, sodium sulfate decahydrate dendrites growing from solution produce convective plumes which lead to higher tip growth rate only as the crystal growth direction approaches that of gravity. Convective plumes are laminar for small crystals under conditions of these experiments; the rise velocity of such plumes is greater than individual vortex rings under identical conditions. Convection effects are only present in solution under a critical supercooling less than about 5 C for sodium sulfate and 2 C for ice in NaCl since at higher supercooling the crystallization velocity, proportional to the square of the supercooling, exceeds the convective velocity, proportional to the square root of the supercooling. The role of convective velocity in bulk solidification is to give a large scale flow which under extreme cases may lead to extensive secondary crystal production, which alters the resulting crystal texture of the completely solidified melt.

Hallett, J.↗
NASA NTRS2000

Micromechanical Characterization and Texture Analysis of Direct Cast Titanium Alloys Strips

This research was conducted to determine a post-processing technique to optimize mechanical and material properties of a number of Titanium based alloys and aluminides processed via Melt Overflow Solidification Technique (MORST). This technique was developed by NASA for the development of thin sheet titanium and titanium aluminides used in high temperature applications. The materials investigated in this study included conventional titanium alloy strips and foils, Ti-1100, Ti-24Al-11Nb (Alpha-2), and Ti-48Al-2Ta (Gamma). The methodology used included micro-characterization, heat-treatment, mechanical processing and mechanical testing. Characterization techniques included optical, electron microscopy, and x-ray texture analysis. The processing included heat-treatment and mechanical deformation through cold rolling. The initial as-cast materials were evaluated for their microstructure and mechanical properties. Different heat-treatment and rolling steps were chosen to process these materials. The properties were evaluated further and a processing relationship was established in order to obtain an optimum processing condition. The results showed that the as-cast material exhibited a Widmanstatten (fine grain) microstructure that developed into a microstructure with larger grains through processing steps. The texture intensity showed little change for all processing performed in this investigation.

Source record↗
NASA NTRS1983

Materials processing in the reduced-gravity environment of space

Studies of the effects of gravitation on the behavior of fluids and the shapes of materials for the years 1977-1982 are reviewed, with a focus on ground-based research which complements and gives direction to experimentation in the reduced-gravity environment of space. Fluid-behavior topics discussed include crystal growth from melts and from vapor, dendritic solidification and casting, multiphase alloy solidification, electrophoresis, convection behavior, and special heat-flow considerations characteristic of the space environment. With regard to solids, such subjects as containerless positioning technology and its applications (in glass preparation, liquid drop and shell studies, nucleation experiments, and measurements of fundamental properties of molten reactants), liquid floating zones, solid self-deformation, and sedimentation and buoyancy effects are considered and illustrated.

Carruthers, J. R.↗
NASA NTRS2024

FLUTE: Fluidic Telescope

The future of space-based UV/optical/IR astronomy requires ever larger telescopes. The highest priority astrophysics targets (including Earth-like exoplanets, first generation stars, and early galaxies) are all extremely faint, which presents an ongoing challenge for current missions and is the opportunity space for next generation telescopes: larger telescopes are the primary way to address this issue. The FLUTE project aims to revolutionize space astronomy (and in-space manufacturing of high-precision optics for a variety of other applications) by leveraging the physics of wetting and hydrostatic phenomena in microgravity. The approach being developed by the team uses surface tension to shape a liquid into a desired optical form with sub-nanometer surface quality. A liquid with appropriate optical properties is brought into contact with a high affinity bounding frame, resulting in pinning of the liquid to the frame. In microgravity, the shape of the free surface is dictated solely by surface tension, thus assuming the shape of a spherical cap. Further dynamic control over the shape is possible through changing the liquid volume, the frame geometry, and — if desired — with the addition of external forces (e.g., electromagnetic forces). The approach is scale-invariant and is expected to enable space telescopes with optical apertures measuring in tens or even hundreds of meters, allowing, for instance, direct imaging of extra-solar planets. Both refractive and reflective optical components can be created using this approach. If the liquid’s properties enable solidification (e.g., a liquid metal), the resulting component can then become an optical-grade solid object, without post-processing steps. The approach has been successfully validated in a laboratory neutral buoyancy environment, in parabolic microgravity flights, and in experiments aboard the International Space Station (ISS). FLUTE is a collaboration between NASA Ames Research Center, NASA Goddard Space Flight Center, and Technion – Israel Institute of Technology. More on information on FLUTE can be found at https://www.nasa.gov/science-research/astrophysics/what-is-the-fluidic-telescope/. This presentation provides an update on the project's accomplishments to-date and discusses next steps.

Space observatory↗
NASA NTRS1980

Novel duplex vapor-electrochemical method for silicon solar cells

A process was developed for the economic production of high purity Si from inexpensive reactants, based on the Na reduction of SiF4 gas. The products of reaction (NaF, Si) are separated by either aqueous leaching or by direct melting of the NaF-Si product mixture. Impurities known to degrade solar cell performance are all present at sufficiently low concentrations so that melt solidification (e.g., Czochralski) will provide a silicon material suitable for solar cells.

Nanis, L.↗
NASA NTRS1986

Behavior of insoluble particles during parabolic flight solidification processing of Fe-C-Si and Fe-C-V alloys

In a high-g rapid solidification environment, Fe-base alloy insoluble particles at the solidification interface may be pushed ahead of the interface or may be trapped in the solid, depending on the correlation of various interface energies, the solidification rates, and the Stokes force; particle agglomeration due to buoyancy-driven convection further complicates the problem. Attention is presently given to results obtained for directionally solidified Fe-C-Si and Fe-C-V alloys during parabolic low-g flight and ground experiments. In these systems, graphite and vanadium carbide can be considered to be the insoluble particles.

Stefanescu, D. M.↗
NASA NTRS1990

Secondary arm coarsening and microsegregation in superalloy PWA-1480 single crystals: Effect of low gravity

Single crystal specimens of nickel base superalloy PWA-1480 were directionally solidified on ground and during low gravity (20 sec) and high gravity (90 sec) parabolic maneuver of KC-135 aircraft. Thermal profiles were measured during solidification by two in-situ thermocouples positioned along the sample length. The samples were quenched during either high or low gravity cycles so as to freeze the structures of the mushy zone developing under different gravity levels. Microsegregation was measured by examining the solutal profiles on several transverse cross-sections across primary dendrites along their length in the quenched mushy zone. Effect of gravity level on secondary arm coarsening kinetics and microsegregation have been investigated. The results indicate that there is no appreciable difference in the microsegregation and coarsening kinetics behavior in the specimens grown under high or low gravity. This suggests that short duration changes in gravity/levels (0.02 to 1.7 g) do not influence convection in the interdendritic region. Examination of the role of natural convection, in the melt near the primary dendrite tips, on secondary arm spacings requires low gravity periods longer than presently available on KC-135. Secondary arm coarsening kinetics show a reasonable fit with the predictions from a simple analytical model proposed by Kirkwood for a binary alloy.

Vijayakumar, M.↗
DOE OSTI2023

Strength mechanisms and tunability in Al-Ce-Mg ternary alloys enabled by additive manufacturing

Al-Ce-based alloys are promising candidates for additive manufacturing (AM) due to their hot-cracking resistance and because they do not require heat treatment to obtain precipitation strengthening. Rapid solidification rates enabled by AM methods can lead to enhanced mechanical properties; however, the strengthening mechanisms over large composition ranges were unclear. Here, combinatorial synthesis by directed-energy deposition (DED) and hardness measurements were used to rapidly map the composition-dependent strength of the ternary Al-Ce-Mg system. Tensile testing and microstructure characterization of selected compositions were performed to elucidate the compositional dependence of the strengthening mechanisms. Al 11 Ce 3 precipitates were present in all cases, and the maximum hardness (1.25 GPa) was measured for the Al-8Ce-10Mg composition. A combination of (i) Hall-Petch strengthening, based on the FCC-matrix-phase cell size; (ii) particle strengthening, based on Al 11 Ce 3 volume fraction and size; and (iii) solid-solution strengthening, based on Mg composition of the matrix phase, were used to account for the measured strengths. Vickers hardness is shown to correlate well with ultimate tensile strength in these alloys, highlighting the value of surface-based techniques for rapid screening.

36 MATERIALS SCIENCE↗
NASA NTRS2006

Experiments Conducted Aboard the International Space Station: The Pore Formation and Mobility Investigation (PFMI) and the In-Space Soldering Investigation (ISSI): A Current Study of Results

Experiments in support of the Pore Formation and Mobility Investigation (PFMI) and the In-Space Soldering Investigation (ISSI) were conducted aboard the International Space Station (ISS) with the goal of promoting our fundamental understanding of melting dynamics , solidification phenomena, and defect generation during materials processing in a microgravity environment. Through the course of many experiments a number of observations, expected and unexpected, have been directly made. These include gradient-driven bubble migration, thermocapillary flow, and novel microstructural development. The experimental results are presented and found to be in good agreement with models pertinent to a microgravity environment. Based on the space station results, and noting the futility of duplicating them in Earth s unit-gravity environment, attention is drawn to the role ISS experimentslhardware can play to provide insight to potential materials processing techniques and/or repair scenarios that might arise during long duration space transport and/or on the lunar/Mars surface.

Grugel, R. N.↗
DOE OSTI2017

Direct Cast U-6Nb – 2017 Progress on Cylindrical Castings

This report describes work to further develop a sound technical basis and best practices for mold design and process parameters for the Direct Casting of U-6wt%Nb components. One major challenge to the production of U-6Nb components is the propensity for niobium segregation during casting and solidification. This is especially true for cylindrical castings where the vertical side walls allow flotation of Nb resulting in severe inverse macrosegregation. In this work, a small (120 mm diameter by 180 mm tall) and large cylinder (250 mm diameter by 310 mm tall) are examined with a focus on reducing, or eliminating, niobium segregation. It is demonstrated that counter gravity casting (top-to-bottom solidification) can be used to minimize segregation in the small cylinder. Attempts to counter gravity cast the large cylinder were unsuccessful, in large part due to size limitations of the current furnace. A path forward for casting of the large cylinders is discussed.

42 ENGINEERING↗
NASA NTRS1986

Compositional redistribution during casting of Hg sub 0.8 Cd sub 0.2 Te alloys

A series of Hg(0.8)Cd(0.2)Te ingots was cast both vertically and horizontally under well-defined thermal conditions by using a two-zone furnace with isothermal heat-pipe liners. The main objective of the experiments was to establish correlations between casting parameters and compositional redistribution and to develop ground-based data for a proposed flight experiment of casting of Hg(1-x)Cd(x)Te alloys under reduced gravity conditions. The compositional variations along the axial and radial directions were determined by precision density measurements, infrared transmission spectra, and X-ray energy dispersion spectrometry. Comparison between the experimental results and a numerical simulation of the solidification process of Hg(0.8)Cd(0.2)Te is described.

Su, Ching-Hua↗
NASA NTRS1988

Compositional redistribution during casting of Hg(0.8)Cd(0.2)Te alloys

A series of Hg(0.8)Cd(0.2)Te ingots was cast both vertically and horizontally under well-defined thermal conditions by using a two-zone furnace with isothermal heat-pipe liners. The main objective of the experiments was to establish correlations between casting parameters and compositional redistribution and to develop ground-based data for a proposed flight experiment of casting of Hg(1-x)Cd(x)Te alloys under reduced gravity conditions. The compositional variations along the axial and radial directions were determined by precision density measurements, infrared transmission spectra, and X-ray energy dispersion spectrometry. Comparison between the experimental results and a numerical simulation of the solidification process of Hg(0.8)Cd(0.2)Te is described.

Su, Ching-Hua↗
NASA NTRS1998

The Isothermal Dendritic Growth Experiment

The growth of dendrites is one of the commonly observed forms of solidification encountered when metals and alloys freeze under low thermal gradients, as occurs in most casting and welding processes. In engineering alloys, the details of the dendritic morphology directly relates to important material responses and properties. Of more generic interest, dendritic growth is also an archetypical problem in morphogenesis, where a complex pattern evolves from simple starting conditions. Thus, the physical understanding and mathematical description of how dendritic patterns emerge during the growth process are of interest to both scientists and engineers. The Isothermal Dendritic Growth Experiment (IDGE) is a basic science experiment designed to measure, for a fundamental test of theory, the kinetics and morphology of dendritic growth without complications induced by gravity-driven convection. The IDGE, a collaboration between Rensselaer Polytechnic Institute, in Troy NY, and NASA's Lewis Research Center (LeRC) was developed over a ten year period from a ground-based research program into a space flight experiment. Important to the success of this flight experiment was provision of in situ near-real-time teleoperations during the spaceflight experiment.

Glicksman, M. E.↗
DOE OSTI2018

On the formation mechanism of the ring-like microstructure of high-pressure die-cast A390 alloy

Highlights: • High-pressure die casting A390 alloy exhibited ring-like microstructure consisted of PSPs-free and PSPs-rich zones. • With 3D data, the size and morphology distribution of PSPs showed similar tendency regardless of the location. • The latent heat released from the PSPs led to the formation of ring-like band. • Widely observed defect band was inhibited because of the precipitation and growth of PSPs during solidification. - Abstract: The microstructure of the A390 alloy during high pressure die casting (HPDC), including pores, primary silicon particles (PSPs) and Cu-rich phases was characterized using synchrotron X-ray tomography. On the cross section of the sample exhibited ring-like or band microstructure, which comprised multiple PSPs-free and PSPs-rich zones. The PSPs distributed evenly in both size and morphology regardless of the ring-like microstructure. The size of aluminum dendrites changed according to the location of the ring-like microstructure, and was highly dependent on the local latent heat released from the PSPs as well as the distribution of the ‘net’ Cu-rich phases. Along the radial direction of the sample exhibited an abrupt increase of pores, indicating a tendency for forming a defect band in but such tendency was inhibited because of the huge amount of latent heat released by the PSPs during solidification, which was quite different from that of either magnesium alloys or hypoeutectic aluminum alloys.

36 MATERIALS SCIENCE↗