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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Petrov-Galerkin methods for natural convection in directional solidification of binary alloys

A Petrov-Galerkin finite element method is presented for calculation of the steady, axisymmetric thermosolutal convection and interface morphology in a model for vertical Bridgman crystal growth of nondilute binary alloys. The Petrov-Galerkin method is based on the formulation for biquadratic elements developed by Heinrich and Zienkiewicz and is introduced into the calculation of the velocity, temperature and concentration fields. The algebraic system is solved simultaneously for the field variables and interface shape by Newton's method. The results of the Petrov-Galerkin method are compared critically with those of Galerkin's method using the same finite element grids. Significant improvements in accuracy are found with the Petrov-Galerkin method only when the mesh is refined and when the formulation of the residual equations is modified to account for the mixed boundary conditions that arise at the solidification interface. Calculations for alloys with stable and unstable solute gradients show the occurrence of classical flow transitions and morphological instabilities in the solidification system.

Adornato, Peter M.↗
NASA NTRS1999

Crystal Growth of II-VI Semiconducting Alloys by Directional Solidification

This research study is investigating the effects of a microgravity environment during the crystal growth of selected II-VI semiconducting alloys on their compositional, metallurgical, electrical and optical properties. The on-going work includes both Bridgman-Stockbarger and solvent growth methods, as well as growth in a magnetic field. The materials investigated are II-VI, Hg(1-x)Zn(x)Te, and Hg(1-x)Zn(x)Se, where x is between 0 and 1 inclusive, with particular emphasis on x-values appropriate for infrared detection and imaging in the 5 to 30 micron wavelength region. Wide separation between the liquidus and solidus of the phase diagrams with consequent segregation during solidification and problems associated with the high volatility of one of the components (Hg), make the preparation of homogeneous, high-quality, bulk crystals of the alloys an extremely difficult nearly an impossible task in a gravitational environment. The three-fold objectives of the on-going investigation are as follows: (1) To determine the relative contributions of gravitationally-driven fluid flows to the compositional redistribution observed during the unidirectional crystal growth of selected semiconducting solid solution alloys having large separation between the liquidus and solidus of the constitutional phase diagram; (2) To ascertain the potential role of irregular fluid flows and hydrostatic pressure effects in generation of extended crystal defects and second-phase inclusions in the crystals; and, (3) To obtain a limited amount of "high quality" materials needed for bulk crystal property characterizations and for the fabrication of various device structures needed to establish ultimate material performance limits. The flight portion of the study was to be accomplished by performing growth experiments using the Crystal Growth Furnace (CGF) manifested to fly on various Spacelab missions.

Lehoczky, Sandor L.↗
NASA NTRS2003

Melt Flow Control in the Directional Solidification of Binary Alloys

Our main project objectives are to develop computational techniques based on inverse problem theory that can be used to design directional solidification processes that lead to desired temperature gradient and growth conditions at the freezing front at various levels of gravity. It is known that control of these conditions plays a significant role in the selection of the form and scale of the obtained solidification microstructures. Emphasis is given on the control of the effects of various melt flow mechanisms on the local to the solidification front conditions. The thermal boundary conditions (furnace design) as well as the magnitude and direction of an externally applied magnetic field are the main design variables. We will highlight computational design models for sharp front solidification models and briefly discuss work in progress toward the development of design techniques for multi-phase volume-averaging based solidification models.

Zabaras, Nicholas↗
NASA NTRS1992

Microstructural development during directional solidification of peritectic alloys

Despite the widespread commercial use of peritectic alloys (e.g., steels, brass, bronze, intermetallic compounds, Co based superalloys and A3B type superconductors), the characterization of the microstructural development during directional solidification of peritectics has historically lagged behind similar efforts directed towards other types of binary invariant reactions such as eutectic or monotectic. A wide variety of possible microstructures has been shown to form in peritectics depending upon the imposed temperature gradient, G, the solidification velocity, V, as well as the presence or absence of convection in the melt. This has important technological implications since many commercially important alloys exhibit peritectics and processing methods such as casting and welding often involve widely changing conditions. It has been the aim of this project to examine, in a systematic fashion, both experimentally and theoretically, the influence of gravitationally driven convection on segregation and microstructural development during solidification in peritectic systems under terrestrial conditions. The scientific results of the project will be used to establish ground based data in support of a meaningful microgravity flight experiment.

Lograsso, Thomas A.↗
NASA NTRS2000

Novel Directional Solidification of Hypermonotectic Alloys

There are many metal alloy systems that separate into two different liquids upon cooling from a higher temperature. Uniform microstructural development during solidification of these immiscible liquids on Earth is hampered by inherent density differences between the phases. Microgravity processing minimizes settling but segregation still occurs due to gravity independent wetting and coalescence phenomena. Experiments with the transparent organic, metal analogue, succinonitrile-glycerol system were conducted in conjunction with applied ultrasonic energy. The processing parameters associated with this technique have been evaluated in view of optimizing dispersion uniformity. Characterization of the experimental results in terms of an initial modeling effort will also be presented.

Grugel, Richard N.↗
NASA NTRS2001

Novel Directional Solidification of Hypermonotectic Alloys

There are many metal alloy systems that separate into two different liquids upon cooling from a higher temperature. Uniform microstructural development during solidification of these immiscible liquids on Earth is hampered by inherent density differences between the phases. Microgravity processing minimizes settling but segregation still occurs due to gravity independent wetting and coalescence phenomena. Experiments with the transparent organic, metal analogue, succinonitrile-glycerol system were conducted in conjunction with applied ultrasonic energy. The processing parameters associated with this technique have been evaluated in view of optimizing dispersion uniformity. Characterization of the experimental results in terms of an initial modeling effort will also be presented.

Grugel, R. N.↗
NASA NTRS1999

Directional Solidification of a Binary Alloy into a Cellular Convective Flow: Localized Morphologies

A steady, two dimensional cellular convection modifies the morphological instability of a binary alloy that undergoes directional solidification. When the convection wavelength is far longer than that of the morphological cells, the behavior of the moving front is described by a slow, spatial-temporal dynamics obtained through a multiple-scale analysis. The resulting system has a "parametric-excitation" structure in space, with complex parameters characterizing the interactions between flow, solute diffusion, and rejection. The convection stabilizes two dimensional disturbances oriented with the flow, but destabilizes three dimensional disturbances in general. When the flow is weak, the morphological instability behaves incommensurably to the flow wavelength, but becomes quantized and forced to fit into the flow-box as the flow gets stronger. At large flow magnitudes the instability is localized, confined in narrow envelopes with cells traveling with the flow. In this case the solutions are discrete eigenstates in an unbounded space. Their stability boundary and asymptotics are obtained by the WKB analysis.

Chen, Y.- J.↗
NASA NTRS1989

Morphological instabilities in directional solidification of a binary alloy - End effects

This paper considers the unidirectional solidification of a binary alloy for which the liquid and solid phases are bounded by endwalls. In order to account for the transport of latent heat and solute, thermal and solutal boundary layers must be placed at the solidifying interface. Further, under the assumption of fixed temperature gradients, the presence of the endwalls leads to a velocity of solidification that decreases with time, and hence to an unsteady basic state having a planar interface. From a stability analysis of this state, a nonlinear long-wave evolution equation of Sivashinsky type is derived, with modified coefficients, that shows how the onset of cellular structure is delayed by the presence of endwalls.

Young, Gerald W.↗
NASA NTRS1993

Solidification of eutectic system alloys in space (M-19)

It is well known that in the liquid state eutectic alloys are theoretically homogeneous under 1 g conditions. However, the homogeneous solidified structure of this alloy is not obtained because thermal convection and non-equilibrium solidification occur. The present investigators have clarified the solidification mechanisms of the eutectic system alloys under 1 g conditions by using the in situ observation method; in particular, the primary crystals of the eutectic system alloys never nucleated in the liquid, but instead did so on the mold wall, and the crystals separated from the mold wall by fluid motion caused by thermal convection. They also found that the equiaxed eutectic grains (eutectic cells) are formed on the primary crystals. In this case, the leading phase of the eutectic must agree with the phase of the primary crystals. In space, no thermal convection occurs so that primary crystals should not move from the mold wall and should not appear inside the solidified structure. Therefore no equiaxed eutectic grains will be formed under microgravity conditions. Past space experiments concerning eutectic alloys were classified into two types of experiments: one with respect to the solidification mechanisms of the eutectic alloys and the other to the unidirectional solidification of this alloy. The former type of experiment has the problem that the solidified structures between microgravity and 1 g conditions show little difference. This is why the flight samples were prepared by the ordinary cast techniques on Earth. Therefore it is impossible to ascertain whether or not the nucleation and growth of primary crystals in the melt occur and if primary crystals influence the formation of the equiaxed eutectic grains. In this experiment, hypo- and hyper-eutectic aluminum copper alloys which are near eutectic point are used. The chemical compositions of the samples are Al-32.4mass%Cu (Hypo-eutectic) and Al-33.5mass%Cu (hyper-eutectic). Long rods for the samples are cast by the Ohno Continuous Casting Process and they show the unidirectionally solidified structure. Each flight and ground sample was made of these same rods. The dimensions of all samples are 4.5 mm in diameter and 23.5 mm in length. Each sample is put in a graphite capsule and then vacuum sealed in a double silica ampoule. Then the ampoule is put in the tantalum cartridge and sealed by electron beam welding. For onbard experiments, a Continuous Heating Furnance (CHF) will be used for melting and solidifying samples under microgravity conditions. Six flight samples will be used. Four samples are hypo-eutectic and two are hyper-eutectic alloys. The surface of the two hypo-eutectic alloy samples are covered with aluminum oxide film to prevent Marangoni convection expected under microgravity conditions. Each sample will be heated to 700 C and held at that temperature for 5 min. After that the samples will be allowed to cool to 500 C in the furnace and they will be taken out of the furnace for He gas cooling. The heating and cooling diagrams for the flight experiments are shown. After collecting the flight samples, the solidified structures of the samples will be examined and the mechanisms of eutectic solidification under microgravity conditions will be determined. It is likely that successful flight experiment results will lead to production of high quality eutectic alloys and eutectic composite materials in space.

Ohno, Atsumi↗
NASA NTRS1983

Directional Solidification of Monotectic Alloys

Cooling at certain rates produced fibrous composite structures. Alloy samples melted in alumina or graphite crucibles under argon and then chillcast into 33-mm-diameter rods or sucked directly into 3-mm-bore alumina or silica tubes. Alloying not automatic with immiscible components of different densities and widely different melting points.

Hellawell, A.↗
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 NTRS1988

Dendritic solidification in binary alloys

Alloys generally solidify dendritically, and associated with that is the microsegregation of impurities. Pure metals also solidify in dendritic form as 'thermal' dendrites, which actually segregate the system's enthalpy. In this investigation, small additions of solute to succinonitrile have been studied and dendritic growth observed in a supercooled melt. This free dendritic growth-mode is similar to that experienced by equiaxed dendrites found in alloy castings. Observations of these free dendrites include measurement of velocity and tip radius of the dendrites at different supercoolings and solute concentrations.

Chopra, M. A.↗
NASA NTRS1990

Solidification processing of alloys using an applied electric field

A method is provided for obtaining an alloy having an ordered microstructure which comprises the steps of heating the central portion of the alloy under uniform temperature so that it enters a liquid phase while the outer portions remain solid, applying a constant electric current through the alloy during the heating step, and solidifying the liquid central portion of the alloy by subjecting it to a temperature-gradient zone so that cooling occurs in a directional manner and at a given rate of speed while maintaining the application of the constant electric current through the alloy. The method of the present invention produces an alloy having superior characteristics such as reduced segregation. After subsequent precipitation by heat-treatment, the alloys produced by the present invention will have excellent strength and high-temperature resistance.

Mckannan, Eugene C.↗
NASA NTRS2001

Cellular Spacing Selection During the Directional Solidification of Binary Alloys. A Numerical Approach

The evolution of cellular solid/liquid interfaces from an initially unstable planar front was studied by means of a two-dimensional computer simulation. The developed numerical model makes use of an interface tracking procedure and has the capability to describe the dynamics of the interface morphology based on local changes of the thermodynamic conditions. The fundamental physics of this formulation was validated against experimental microgravity results and the predictions of the analytical linear stability theory. The performed simulations revealed that in certain conditions, based on a competitive growth mechanism, an interface could become unstable to random perturbations of infinitesimal amplitude even at wavelengths smaller than the neutral wavelength, lambda(sub c), predicted by the linear stability theory. Furthermore, two main stages of spacing selection have been identified. In the first stage, at low perturbations amplitude, the selection mechanism is driven by the maximum growth rate of instabilities while in the second stage the selection is influenced by nonlinear phenomena caused by the interactions between the neighboring cells. Comparison of these predictions with other existing theories of pattern formation and experimental results will be discussed.

Catalina, Adrian V.↗
NASA NTRS1992

Directional solidification processing of alloys using an applied electric field

A method is provided for obtaining an alloy having an ordered microstructure which comprises the steps of heating the central portion of the alloy under uniform temperature so that it enters a liquid phase while the outer portions remain solid, applying a constant electric current through the alloy during the heating step, and solidifying the liquid central portion of the alloy by subjecting it to a temperature-gradient zone so that cooling occurs in a directional manner and at a given rate of speed while maintaining the application of the constant electric current through the alloy. The method is particularly suitable for use with nickel-based superalloys. The method of the present invention produces an alloy having superior characteristics such as reduced segregation. After subsequent precipitation by heat-treatment, the alloys produced by the present invention will have excellent strength and high-temperature resistance.

McKannan, Eugene C.↗