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At least 127 records · Page 7

Leveraging Artificial Intelligence to Predict Novel Eutectic Alloys

The goal of this project was to train an artificial neural network (ANN) to predict the fractional composition and melting point of eutectic alloys using fundamental atomic properties as inputs. The fundamental properties considered include atomic number, atomic weight, atomic radius, valence electron concentration, electronegativity, and electron affinity. The project involved several phases, starting with data preparation, where phase diagram data was harvested from the ASM International database. Approximately 1300 binary eutectics were collected and cleaned to ensure relevance and accuracy. A regression model was selected for training, utilizing a rectified linear unit as the activation function. Various model configurations were evaluated for predictive accuracy, with validation techniques employed to ensure robustness. The model demonstrated predictive capabilities above random guessing and was able to achieve up to 11% accuracy under certain conditions. An ablative test identified atomic radius and valence electron concentration as critical inputs for model performance. Incorporating the melting point of atomic constituents improved accuracy significantly, although ultimately the model’s predictive capability still fell short of the 80% target. This report details the methodology, results, and implications of the research, contributing to the understanding of employing artificial intelligence to predict the phase transition behavior of eutectic alloys.

36 MATERIALS SCIENCE↗

Eutectic superalloys strengthened by aligned delta, Ni3Cb lamellae, gamma-prime, Ni3Al precipitates and reduced interlamellar spacing.

Monovariant eutectic alloys, located on the liquidus trough between the binary eutectic gamma, Ni - delta, Ni3Cb and the ternary eutectic gamma, Ni - gamma-prime, Ni3Al - delta, Ni3Cb, were identified which permitted the production of aligned lamellae within a nickel solid solution matrix containing the precipitate gamma-prime. These alloys exhibited great insensitivity in their composite microstructures to solidification parameters such as growth rate temperature gradient, and were found to be remarkably uniform in composition along their length.

Lemkey, F. D.↗

Zero-gravity growth of NaF-NaCl eutectics in the NASA Skylab program

Continuous and discontinuous NaF fibers, embedded in a NaCl matrix, were produced in space and on earth. The production of continuous fibers in a eutectic mixture is attributed to the absence of convection current in the liquid during solidification in space. Image transmission and optical transmittance measurements of transverse sections of the space-grown and earth-grown ingots were made with a light microscope and a spectrometer. It is shown that better optical properties were obtained from samples grown in space. This was attributed to a better alignment of NaF fibers along the ingot axis. A new concept is advanced to explain the phenomenon of transmittance versus far infrared wavelength of the directionally solidified NaCl-NaF eutectic in terms of the two-dimensional Bragg Scattering and the polarization effect of Rayleigh scattering. This concept can be applied to other eutectic systems as long as the index of refraction of the matrix over a range of wavelengths is known. Experimental data are in agreement with the theoretical prediction.

Yue, A. S.↗

Refinement of Promising Coating Compositions for Directionally Cast Eutectics

The successful application of high creep strength, directionally solidified gamma/gamma prime-delta (Ni-19.7Cb-6Cr-2.5Al) eutectic superalloy turbine blades requires the development of suitable coatings for airfoil, root and internal blade surfaces. In order to improve coatings for the gamma/gamma prime-delta alloy, the current investigation had the goals of (1) refining promising coating compositions for directionally solidified eutectics, (2) evaluating the effects of coating/ substrate interactions on the mechanical properties of the alloy, and (3) evaluating diffusion aluminide coatings for internal surfaces. Burner rig cyclic oxidation, furnace cyclic hot corrosion, ductility, and thermal fatigue tests indicated that NiCrAlY+Pt(63 to 127 micron Ni-18Cr-12Al-0.3Y + 6 micron Pt) and NiCrAlY(63 to 127 micron Ni-18Cr-12Al-0.3Y) coatings are capable of protecting high temperature gas path surfaces of eutectic alloy airfoils. Burner rig (Mach 0.37) testing indicated that the useful coating life of the 127 micron thick coatings exceeded 1000 hours at 1366 K (2000 deg F). Isothermal fatigue and furnance hot corrosion tests indicated that 63 micron NiCrAlY, NiCrAlY + Pt and platinum modified diffusion aluminide (Pt + Al) coating systems are capable of protecting the relatively cooler surfaces of the blade root. Finally, a gas phase coating process was evaluated for diffusion aluminizing internal surfaces and cooling holes of air-cooled gamma/gamma prime-delta turbine blades.

Strangman, T. E.↗

Directionally solidified eutectic alloy gamma-beta

A pseudobinary eutectic alloy composition was determined by a previously developed bleed-out technique. The directionally solidified eutectic alloy with a composition of Ni-37.4Fe-10.0Cr-9.6Al (in wt%) had tensile strengths decreasing from 1,090 MPa at room temperature to 54 MPa at 1,100 C. The low density, excellent microstructural stability, and oxidation resistance of the alloy during thermal cycling suggest that it might have applicability as a gas turbine vane alloy while its relatively low high temperature strength precludes its use as a blade alloy. A zirconium addition increased the 750 C strength, and a tungsten addition was ineffective. The gamma=beta eutectic alloys appeared to obey a normal freezing relation.

Tewari, S. N.↗

Directionally solidified eutectic gamma plus beta nickel-base superalloys

A directionally solidified multivariant eutectic gamma + beta nickel-base superalloy casting having improved high temperature strength and oxidation resistance properties is provided. This comprises a two phase eutectic structure containing, on a weight percent basis, 5.0-15.0 tungsten, 8.5-14.5 aluminum, 0.0-35.0 cobalt and the balance being nickel. Embedded within the gamma phase nickel-base matrix are aligned eutectic beta phase (primarily (NiCo)Al reinforcing lamellae.

Jackson, M. R.↗

Directionally solidified eutectic gamma-gamma nickel-base superalloys

A directionally solidified multivariant eutectic gamma-gamma prime nickel-base superalloy casting having improved high temperature properties was developed. The alloy is comprised of a two phase eutectic structure consisting essentially of on a weight percent base, 6.0 to 9.0 aluminum, 5.0 to 17.0 tantalum, 0-10 cobalt, 0-6 vanadium, 0-6 rhenium, 2.0-6.0 tungsten, and the balance being nickel, subject to the proviso that the sum of the atomic percentages of aluminum plus tantalum is within the range of from 19-22, and the ratio of atomic percentages of tantalum to aluminum plus tantalum is within the range of from 0.12 to 0.23. Embedded within the gamma nickel-base matrix are aligned eutectic gamma prime phase (primarily nickel-aluminum-tantalum) reinforcing fibers.

Jackson, M. R.↗

Directionally solidified ceramic eutectics

The aligned structures which result from the directional solidification (DS) of ceramic eutectics are of interest because of their potential for use in electronic devices and as structural materials. Techniques for growing DS ceramic eutectics are briefly discussed. The principles and controlling parameters of DS eutectic growth are described. The criteria for plane-front growth and the effect of growth rate on interlamellar or interfiber spacing are discussed. Examples of the effect of growth parameters on the alignment of the microstructure are given. Examples of the mechanical properties of directionally solidified oxide-oxide ceramics are also cited.

Ashbrook, R. L.↗

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.↗

Directional solidification of Al2-Cu-Al and Al3-Ni-Al eutectics during TEXUS rocket flight

One lamellar eutectic sample and one fiber-like eutectic sample were solidified directionally during the TEXUS-6 rocket flight. The microstructures and the results of the thermal analysis, obtained from the temperatures recorded on the cartridge skin, are compared. No appreciable modifications of the regularity of the eutectic structures were observed by passing from 1 g to 0.0001 g in these experiments. No steady state growth conditions were achieved in these experiments.

Favier, J. J.↗

Study of eutectic formation

A theory was developed for the influence of convection on the microstructure of lamellar eutectics. Convection is predicted to produce a coarser microstructure, especially at low freezing rates and large volume fractions of the minority phase. Similary convection is predicted to lower the interfacial undercooling, especially at low freezing rates. Experiments using spin-up/spin-down were performed on the Mn-Bi eutectic. This stirring had a dramatic effect on the microstructure, not only making it coarser but at low freezing rates also changing the morphology of the MnBi. The coarsering persisted to moderately high freezing rates. At the lowest freezing rate, vigorous stirring caused the MnBi to be concentrated at the periphery of the ingot and absent along the center. Progress was made on developing a technique for revealing the three-dimensional microstructure of the MnBi eutectic by time-lapse videotaping while etching.

Wilcox, W. R.↗

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.↗

Containerless processing and rapid solidification of Nb-Si alloys in the niobium-rich eutectic range

Containerless processing and rapid solidification techniques were used to process Nb-Si alloys in the Nb-rich eutectic range. Electromagnetically levitated drops were melted and subsequently splat-quenched from different temperatures. A variety of eutectic morphologies was obtained as a function of the degree of superheating or undercooling of the drops prior to splatting. Metallic glass was observed only in drops quenched from above the melting temperature. Microstructures of splats deeply undercooled prior to quenching were very fine and uniform. These results are discussed in terms of classic nucleation theory concepts and the expected heat evolution at different regions of the splat during the rapid quenching process. The locations of the coupled-zone boundaries for the alpha-Nb + Nb3Si eutectic are also suggested.

Hofmeister, W. H.↗

Gravitational influence on eutectic solidification

The effect of gravity on eutectic solidification was investigated experimentally for Pb-Sn binary eutectic alloys. It is found that the separation of the primary crystals of the binary system from the coupled eutectic occurs over a wide range of cooling rates and gravitational fields (100-100,000 g). The separation is strongly influenced by the nucleation behavior of the particular alloy system. A mechanism for the strong phase separation is postulated on the basis of cloud convection models in atmospheric convection.

Sokolowski, Robert S.↗

Microstructural Characterization of a Directionally-Solidified Ni-33 (at. %)Al-31Cr-3Mo Eutectic Alloy as a Function of Withdrawal Rate

The Ni-33 (at. %)Al-3lCr-3Mo eutectic alloy was directionally-solidified (DS) at different rates, V(sub I), varying between 2.5 to 508 mm/ h. Detailed qualitative and quantitative metallographic and chemical analyses were conducted on the directionally-solidified rods. The microstructures consisted of eutectic colonies with parallel lamellar NiAl/(Cr,Mo) plates for solidification rates at and below 12.7 mm/ h. Cellular eutectic microstructures were observed at higher solidification rates, where the plates exhibited a radial pattern. The microstructures were demonstrated to be fairly uniform throughout a 100 mm length of the DS zone by quantitative metallography. The average cell size, bar-d, decreased with increasing growth rate to a value of 125 microns at 508 mm/ h according to the relation bar-d (microns) approx. = 465 V(sup -0.22, sub I), where V(sub I) is in mm/ h. Both the average NiAl plate thickness, bar-Delta(sub NiAl), and the interlamellar spacing, bar-lambda, were observed to be constant for V(sub I) less than or = 50.8 mm/ h but decreased with increasing growth rate above this value as 0.93 bar-Delta(sub NiAl)(microns) = 61.2 V(sup -0.93, sub I) and bar-lambda (microns) = 47.7 V(sup -0.64, sub I), respectively. The present results are detailed on a microstructural map. Keywords Optical microscopy, microstructure, compounds intermetallic, directional solidification

Raj, S. V.↗

Lamellar Spacing Selection in Al-Si Eutectic System: a Theoretical Investigation

It is well known that irregular eutectics such as Al-Si and Fe-C exhibit larger lamellar spacings and undercoolings compared to the predictions made by the Jackson and Hunt (JH) theory. In this paper, we reexamine the JH theory and relax some of the assumptions used in that treatment. The modified theoretical model has enhanced capabilities to predict the lamellar spacing in both regular and irregular eutectics. For the Al-Si system in particular we identified two different spacing selection mechanisms:a) for a particular growth rate, a nearly isothermal interface can be achieved at a unique minimum spacing lambda(sub I); b) the average spacing in the microstructure (lambda(sub av) greater than lambda(sub I)) is essentially dictated by the undercooling of the faceted phase. Based on the modified theoretical model a semi-empirical expression has been developed to account for the influence of the temperature gradient. Application of a Mullin and Sekerka type stability analysis for eutectics will also be presented and the results compared to the modified JH model. It will be shown that the both theoretical approaches are in good agreement with each other and also with the published experimental measurements.

Catalina, Adrian V.↗

A New Analytical Approach to Predict Spacing Selection in Lamellar and Rod Eutectic Systems

In this paper, we reexamine the Jackson and Hunt (JH) theory and relax the assumption of isothermal solid/liquid interface(SLI) used in their treatment. A modification of the term B. in the expression of the solute concentration profile is also proposed. Based on the predictions of this modified theory the traditional definitions of regular and irregular eutectics are discussed. For regular eutectics the new model identifies a range of spacing within the limits defined by the minimum undercooling of the alpha and beta phase. For the irregular Al-Si eutectic system in particular we identified two different spacing selection mechanisnis: a) for a particular growth rate, a nearly isothermal interface can be achieved at a unique minimum spacing lambda(sub I); b) the average spacing in the microstructure (lambda(sub av) > lambda(sub I)) is essentially dictated by the undercooling of the faceted phase. Based on the modified theoretical model a semi-empirical expression has been developed to account for the influence of the temperature gradient. The theoretical calculations have been found to be in good agreement with the published experimental measurements.

Catalina, Adrian V.↗

Kinetic Monte Carlo Simulations of Rod Eutectics and the Surface Roughening Transition in Binary Alloys

In this paper we report on two related topics: Kinetic Monte Carlo simulations of the steady state growth of rod eutectics from the melt, and a study of the surface roughness of binary alloys. We have implemented a three dimensional kinetic Monte Carlo (kMC) simulation with diffusion by pair exchange only in the liquid phase. Entropies of fusion are first chosen to fit the surface roughness of the pure materials, and the bond energies are derived from the equilibrium phase diagram, by treating the solid and liquid as regular and ideal solutions respectively. A simple cubic lattice oriented in the {100} direction is used. Growth of the rods is initiated from columns of pure B material embedded in an A matrix, arranged in a close packed array with semi-periodic boundary conditions. The simulation cells typically have dimensions of 50 by 87 by 200 unit cells. Steady state growth is compliant with the Jackson-Hunt model. In the kMC simulations, using the spin-one Ising model, growth of each phase is faceted or nonfaceted phases depending on the entropy of fusion. There have been many studies of the surface roughening transition in single component systems, but none for binary alloy systems. The location of the surface roughening transition for the phases of a eutectic alloy determines whether the eutectic morphology will be regular or irregular. We have conducted a study of surface roughness on the spin-one Ising Model with diffusion using kMC. The surface roughness was found to scale with the melting temperature of the alloy as given by the liquidus line on the equilibrium phase diagram. The density of missing lateral bonds at the surface was used as a measure of surface roughness.

Bentz, Daniel N.↗