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NASA NTRS1986

Processing-structure characterization of rheocast IN-100 superalloy

The rheocasting solidification process was applied in the production of IN-100 nickel base superalloy, and the effects of processing variables, such as stirring speed, isothermal stirring time, and volume fraction solid during isothermal stirring, on the resultant rheocast structure were investigated. Ingots that were furnace cooled at the same rate but without stirring were compared with the rheocast ingots. Rheocasting yielded fine-grained structures, where the extent of microsegregation, the variation in macrostructure, and the solidification-induced porosity and ingot cracking were found to be reduced in comparison to the unstirred ingots. The grain size and nonuniformity were reduced by increasing the stirring speed, isothermal stirring time, or the volume fraction solid during stirring; decreased microsegregation was achieved by an increase in the volume fraction solid. The structures of grain boundaries lent support to the grain boundary mechanism proposed by Vogel et al. (1977) for rheocasting.

Cheng, Jung-Jen Allen↗

NASA NTRS1990

The Mechanisms of Dispersion Strengthening and Fracture in Al-based XD (TM) Alloys

The influence of reinforcement size, volume fraction, and matrix deformation behavior on room and elevated temperature strength, and the fracture toughness of metal matrix composites of both pure aluminum and Al(4 percent)Cu(1.5 percent)Mg with 0 to 15 vol percent TiB2 were examined. Higher TiB2 volume fractions increased the tensile yield strength both at room and elevated temperatures, and reduced the elongation to fracture. Tensile tests also indicate that small particles provided a greater increase in strength for a given volume fraction than larger particles, whereas elongation to fracture appeared to be insensitive to reinforcement size. The fracture toughness of the Al(4 percent)Cu(1.5 percent)Mg alloys decreased rapidly with TiB2 additions of 0 to 5 vol percent and more slowly with TiB2 additions of 5 to 15 vol percent. Fracture toughness appears to be independent of TiB2 particle size. The isothermal-aging response of the precipitation strengthened Al(4 percent)Cu(1.5 percent)Mg alloys was not altered by the presence of TiB2.

Aiken, R. M., Jr.↗

NASA NTRS2013

Coarsening in Solid-liquid Mixtures: Overview of Experiments on Shuttle and ISS

The microgravity environment on the Shuttle and the International Space Station (ISS) provides the ideal condition to perform experiments on Coarsening in Solid-Liquid Mixtures (CSLM) as deleterious effects such as particle sedimentation and buoyancy-induced convection are suppressed. For an ideal system such as Lead-Tin in which all the thermophysical properties are known, the initial condition in microgravity of randomly dispersed particles with local clustering of solid Tin in eutectic liquid Lead-Tin matrix, permitted kinetic studies of competitive particle growth for a range of volume fractions. Verification that the quenching phase of the experiment had negligible effect of the spatial distribution of particles is shown through the computational solution of the dynamical equations of motion, thus insuring quench-free effects from the coarsened microstructure measurements. The low volume fraction experiments conducted on the Shuttle showed agreement with transient Ostwald ripening theory, and the steady-state requirement of LSW theory was not achieved. More recent experiments conducted on ISS with higher volume fractions have achieved steady-state condition and show that the kinetics follows the classical diffusion limited particle coarsening prediction and the measured 3D particle size distribution becomes broader as predicted from theory.

Ostwald ripening↗

DOE OSTI2021

Influence of O 2 / N 2 oxidizer blends on soot formation and radiative heat flux in PMMA-air 2D slab burner for understanding hybrid rocket combustion

The focus of this study is to establish a correlation between the flame to fuel incident radiative heat flux (RHF) in 1D steady-state diffusion flames to non-intrusively measured RHF in 2D slab burner experiments for a range of O 2 /N 2 oxidizer blends. Slab burner experiments are conducted for a range of increasing O 2 concentrations from 17% to 100% in the oxidizer stream. Non-intrusive two-color pyrometry is used to determine flame temperature, soot volume fraction, and flame to fuel surface RHF. Measurements and modeling confirm soot volume fraction attains a local maximum for an O 2 concentration of 45%. Low-strain diffusion flame modeling shows the reason for the local maximum is the relative location of the soot formation/nucleation fronts relative to oxidation which decreases with increasing O 2 concentration. Overall good agreement between modeling and measurements of radiative heat flux to the fuel is observed for the fuel and range of O 2 concentrations considered. Furthermore, these results demonstrate the viability of using flamelet modeling approaches for describing hybrid rocket motors.

2D slab burner↗

DOE OSTI2024

Exploring 2D X-ray diffraction phase fraction analysis with convolutional neural networks: Insights from kinematic-diffraction simulations

Abstract Deep-learning models are effective for analyzing the complex information in 2D X-ray diffraction (XRD) patterns. Accurately collecting parameters of the material sample is crucial during model training, significantly impacting model performance. In this study, we employ a kinematic-diffraction simulator to generate simulated 2D XRD patterns for Ti–6Al–4V alloy, allowing precise control of sample parameters. These simulated patterns are used to train convolutional neural networks, predicting $$\upbeta$$ β -phase volume fractions. The training data set consists exclusively of 2D XRD patterns with pure $$\upalpha$$ α - or pure $$\upbeta$$ β -phase, while the testing set incorporates patterns with intermediate phase volume fraction. In particular, we investigate how the architectures of the model influence prediction reliability and computational performance. Experimental results reveal that, with appropriate training, the convolutional neural network accurately detects intermediate phase volume fractions even trained with only pure-phase patterns, achieving a mean square error accuracy of $$9.4 \times 10^{-4}$$ 9.4 × 10 - 4 . Graphical abstract

Yue, Weiqi↗

DOE OSTI2020

Effect of copper content on the tensile elongation of Al–Cu–Mn–Zr alloys: Experiments and finite element simulations

Microstructures of cast aluminum alloys used in automotive engine applications often consist of intermetallic particles that can impact the tensile elongation of these alloys. Here in this paper, we investigate the effect of intermetallic grain boundary particles on tensile elongation by fabricating a series of alloys with Cu content varying between 6.0 - 9.0 wt% in cast Al–Cu–Mn–Zr (ACMZ) type compositions. The tensile elongation of as-aged ACMZ alloys decreases monotonically with increase in Cu content. While the microstructure within the grains and yield stress of the alloy remains invariant with Cu content, the decrease in tensile elongation correlates well with increase in the size and volume fraction of grain boundary particles. Microstructural observations are combined with finite element simulations to explain the trend in tensile elongation with changing Cu content. Crack initiation is found to occur by brittle fracture of the grain boundary particles. Increase in particle size promotes crack initiation by reduction in size dependent particle fracture strength. Lower inter-particle spacing at higher particle volume fraction further facilitates crack initiation by increasing stress within the particles caused by the interaction between stress fields of neighboring particles. Increase in particle volume fraction also accelerates crack propagation through the formation of macro shear zones in the microstructure. The increase in Cu content of cast ACMZ alloys, therefore, decreases tensile elongation by promoting both crack initiation and crack propagation.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Measurements of soot formation and hydroxyl concentration in near critical equivalence ratio premixed ethylene flame

The testing and development of existing global and detailed chemical kinetic models for soot formation requires measurements of soot and radical concentrations in flames. A clearer understanding of soot particle inception relies upon the evaluation and refinement of these models in comparison with such measurements. We present measurements of soot formation and hydroxyl (OH) concentration in sequences of flat premixed atmospheric-pressure C2H4/O2/N2 flames and 80-torr C2H4/O2 flames for a unique range of equivalence ratios bracketting the critical equivalence ratio (phi(sub c)) and extending to more heavily sooting conditions. Soot volume fraction and number density profiles are measured using a laser scattering-extinction apparatus capable of resolving a 0.1 percent absorption. Hydroxyl number density profiles are measured using laser-induced fluorescence (LIF) with broadband detection. Temperature profiles are obtained from Rayleigh scattering measurements. The relative volume fraction and number density profiles of the richer sooting flames exhibit the expected trends in soot formation. In near-phi(sub c) visibility sooting flames, particle scattering and extinction are not detected, but an LIF signal due to polycyclic aromatic hydrocarbons (PAH's) can be detected upon excitation with an argon-ion laser. A linear correlation between the argon-ion LIF and the soot volume fraction implies a common mechanistic source for the growth of PAH's and soot particles. The peak OH number density in both the atmospheric and 80-torr flames declines with increasing equivalence ratio, but the profile shape remains unchanged in the transition to sooting, implying that the primary reaction pathways for OH remain unchanged over this transition. Chemical kinetic modeling is demonstrated by comparing predictions using two current reaction mechanisms with the atmospheric flame data. The measured and predicted OH number density profiles show good agreement. The predicted benzene number density profiles correlate with the measured trends in soot formation, although anomalies in the benzene profiles for the richer and cooler sooting flames suggest a need for the inclusion of benzene oxidation reactions.

Inbody, Michael Andrew↗

DOE OSTI2020

A constitutive model for sheared dense suspensions of rough particles

In a concentrated suspension, particles come into contact due to the presence of asperities on their surfaces. As a result, the contact forces and interparticle friction become one of the important factors governing the rheology of rigid particle suspensions at high concentrations. We show that a load-dependent friction model can be used to reproduce the experimentally observed shear thickening [ST—continuous and discontinuous (DST)] behavior with an increase in the asperity size. Increasing the particle surface roughness size leads to a decrease in the critical shear rate above which shear-thickening takes place, a reduction in the critical volume fraction for DST and an increase in the viscosity jump across non-shear-thickened to shear-thickened regime. In this paper, we propose a constitutive model to quantify the effect of increasing the roughness size on the rheology of dense ST suspensions as well as on the critical shear rate for ST and the critical volume fraction for DST. We fit this model to our simulation data for stress controlled shear flow of dense rough particle suspensions. Once the fitting is complete, these equations are used to predict exact volume fractions and shear stress values for transitions between three regimes on the shear stress-shear rate flow state diagram for different roughness values. Furthermore, the results of this study can be used to tune the particle surface roughness for manipulating the dense suspension rheology according to different applications.

42 ENGINEERING↗

NASA NTRS1996

Soot and Radiation Measurements in Microgravity Jet Diffusion Flames

The subject of soot formation and radiation heat transfer in microgravity jet diffusion flames is important not only for the understanding of fundamental transport processes involved but also for providing findings relevant to spacecraft fire safety and soot emissions and radiant heat loads of combustors used in air-breathing propulsion systems. Our objectives are to measure and model soot volume fraction, temperature, and radiative heat fluxes in microgravity jet diffusion flames. For this four-year project, we have successfully completed three tasks, which have resulted in new research methodologies and original results. First is the implementation of a thermophoretic soot sampling technique for measuring particle size and aggregate morphology in drop-tower and other reduced gravity experiments. In those laminar flames studied, we found that microgravity soot aggregates typically consist of more primary particles and primary particles are larger in size than those under normal gravity. Comparisons based on data obtained from limited samples show that the soot aggregate's fractal dimension varies within +/- 20% of its typical value of 1.75, with no clear trends between normal and reduced gravity conditions. Second is the development and implementation of a new imaging absorption technique. By properly expanding and spatially-filtering the laser beam to image the flame absorption on a CCD camera and applying numerical smoothing procedures, this technique is capable of measuring instantaneous full-field soot volume fractions. Results from this technique have shown the significant differences in local soot volume fraction, smoking point, and flame shape between normal and reduced gravity flames. We observed that some laminar flames become open-tipped and smoking under microgravity. The third task we completed is the development of a computer program which integrates and couples flame structure, soot formation, and flame radiation analyses together. We found good agreements between model predictions and experimental data for laminar and turbulent flames under both normal and reduced gravity. We have also tested in the laboratory the techniques of rapid-insertion fine-wire thermocouples and emission pyrometry for temperature measurements. These techniques as well as laser Doppler velocimetry and spectral radiative intensity measurement have been proposed to provide valuable data and improve the modeling analyses.

Ku, Jerry C.↗

NASA NTRS2013

Predicting Bone Mechanical State During Recovery After Long-Duration Skeletal Unloading Using QCT and Finite Element Modeling

During long-duration missions at the International Space Station, astronauts experience weightlessness leading to skeletal unloading. Unloading causes a lack of a mechanical stimulus that triggers bone cellular units to remove mass from the skeleton. A mathematical system of the cellular dynamics predicts theoretical changes to volume fractions and ash fraction in response to temporal variations in skeletal loading. No current model uses image technology to gather information about a skeletal site s initial properties to calculate bone remodeling changes and then to compare predicted bone strengths with the initial strength. The goal of this study is to use quantitative computed tomography (QCT) in conjunction with a computational model of the bone remodeling process to establish initial bone properties to predict changes in bone mechanics during bone loss and recovery with finite element (FE) modeling. Input parameters for the remodeling model include bone volume fraction and ash fraction, which are both computed from the QCT images. A non-destructive approach to measure ash fraction is also derived. Voxel-based finite element models (FEM) created from QCTs provide initial evaluation of bone strength. Bone volume fraction and ash fraction outputs from the computational model predict changes to the elastic modulus of bone via a two-parameter equation. The modulus captures the effect of bone remodeling and functions as the key to evaluate of changes in strength. Application of this time-dependent modulus to FEMs and composite beam theory enables an assessment of bone mechanics during recovery. Prediction of bone strength is not only important for astronauts, but is also pertinent to millions of patients with osteoporosis and low bone density.

Chang, Katarina L.↗

DOE OSTI2026

Emergence of complex-regular eutectic patterns in Al–Ge: Observations from correlative nano-imaging

Eutectic solidification exemplifies nonequilibrium pattern formation, making it a well-studied moving boundary problem. Yet the mechanisms behind the formation of complex-regular microstructures – particularly in highly anisotropic systems with a significant volume fraction of a faceted phase – remain poorly understood. Our understanding of such systems is made complicated by the nonlinear interface kinetics and unique growth dynamics characteristic of faceted phases. To address these challenges, we investigate a model Al–Ge eutectic system, where the faceted Ge phase constitutes a substantial volume fraction (~0.35) and where the two solid phases arrange into so-called “fishbone” or “feather” complex-regular patterns. Using synchrotron-based x-ray nano-imaging and nanotomography with high spatial resolution (22 nm per pixel), we capture in real-time the evolution of the solid–liquid interfaces and the resulting three-dimensional microstructures in this faceted/non-faceted eutectic system. By integrating these observations with electron backscattered diffraction, we elucidate the crystallographic biases on the solidification process and the mechanisms driving the formation of such complex-regular microstructures. These findings inform a new growth model for irregular eutectics in (near-)symmetrical phase diagrams, offering insight on advanced microstructural design and processing strategies. More broadly, we demonstrate how interfacial curvature is generated in irregular eutectic alloys and how it depends on the volume fraction of the faceted phase.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Supersaturating Water with CO 2 via Nanobubble Formation

The subsurface storage of CO 2 is limited by the solubility of CO 2 in brine. One proposed solution to increase the volume fraction of CO 2 in a reservoir is by injecting the CO 2 at high pressure in nanobubble form. These nanobubbles, diameter <50 nm, would be small enough that they would only undergo Brownian motion, preventing them rising under buoyancy and escaping the formation. There has also been some experimental work that suggests the present of these nanobubbles significantly (~2x) increase the solubility of gaseous CO 2 in the aqueous phase. NETL and ExxonMobil will test the viability of this strategy to increase the volume fraction of CO 2 in a subsurface reservoir, determine the stability of these nanobubble systems, and understand the ultimate limits of increasing the CO 2 volume fraction.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRSDate not supplied

Multi-Scale Analysis of Effective Mechanical Properties of Porous 3D Woven Composite Materials

This work aims to compute and analyze the mechanical properties of 3D woven composite materials that share the same yarn structure but differ in their matrix porosity and yarn's fiber volume fraction. Assuming linear elastic behavior, NASA's PuMA software was used to characterize the different composites from their constituents' data, averaging their elastic properties in three main directions to obtain their effective orthotropic mechanical properties. This was performed in three steps: firstly, the porous matrix phase was analyzed at the micro-scale; then, these results were used, along with the mechanical properties of the fibers, to model the yarns at the meso-scale; finally, results from the constituents were homogenized and used to model the mechanical behavior of the unit cell at the macro-scale. The 3D woven composite materials selected for this study are made of a mixture of phenolic resin with porosity values between 0 and 0.6, and infiltrated carbon fiber yarns with fiber volume fractions between 0.5 and 0.8. Results from this study show the effect of different matrix porosities and fiber volume fractions on the macro-scale mechanical properties, and were validated through theoretical and semi-empirical expressions found in the literature.

3D woven materials↗

DOE OSTI2023

Competing Magnetic Interactions and Field-Induced Metamagnetic Transition in Highly Crystalline Phase-Tunable Iron Oxide Nanorods

The inherent existence of multi phases in iron oxide nanostructures highlights the significance of them being investigated deliberately to understand and possibly control the phases. Here, the effects of annealing at 250 °C with a variable duration on the bulk magnetic and structural properties of high aspect ratio biphase iron oxide nanorods with ferrimagnetic Fe3O4 and antiferromagnetic α-Fe2O3 are explored. Increasing annealing time under a free flow of oxygen enhanced the α-Fe2O3 volume fraction and improved the crystallinity of the Fe3O4 phase, identified in changes in the magnetization as a function of annealing time. A critical annealing time of approximately 3 h maximized the presence of both phases, as observed via an enhancement in the magnetization and an interfacial pinning effect. This is attributed to disordered spins separating the magnetically distinct phases which tend to align with the application of a magnetic field at high temperatures. The increased antiferromagnetic phase can be distinguished due to the field-induced metamagnetic transitions observed in structures annealed for more than 3 h and was especially prominent in the 9 h annealed sample. Our controlled study in determining the changes in volume fractions with annealing time will enable precise control over phase tunability in iron oxide nanorods, allowing custom-made phase volume fractions in different applications ranging from spintronics to biomedical applications.

36 MATERIALS SCIENCE↗

NASA NTRS1985

The crystallization of small particles and droplets

A general expression is derived for the volume fraction of material crystallized as a function of time for the situation where boundary effects may be important, and it is applied to a sample consisting of a monodisperse array of small particles. It is assumed that crystallization occurs via homogeneous nucleation followed by crystal growth. The crystallization rate is shown to be controlled by a single dimensionless parameter, beta. Beta exp 1/4 is a dimensionless particle radius which tends to be small when the growth rate is large or when the nucleation rate is small. When beta is large, the general expression for the volume fraction transformed reduces to the standard expression valid for bulk samples. When beta is small, it reduces to the formula used to compute the volume fraction crystallized in droplet undercooling experiments. Hence, the present results are pertinent for the interpretation of some droplet undercooling experiments as well as isothermal DSC and DTA experiments.

Weinberg, M. C.↗

NASA NTRS2005

The Angstrom Exponent and Bimodal Aerosol Size Distributions

Powerlaws have long been used to describe the spectral dependence of aerosol extinction, and the wavelength exponent of the aerosol extinction powerlaw is commonly referred to as the Angstrom exponent. The Angstrom exponent is often used as a qualitative indicator of aerosol particle size, with values greater than two indicating small particles associated with combustion byproducts, and values less than one indicating large particles like sea salt and dust. In this study, we investigate the relationship between the Angstrom exponent and the mode parameters of bimodal aerosol size distributions using Mie theory calculations and Aerosol Robotic Network (AERONET) retrievals. We find that Angstrom exponents based upon seven wavelengths (0.34, 0.38, 0.44, 0.5, 0.67, 0.87, and 1.02 micrometers) are sensitive to the volume fraction of aerosols with radii less then 0.6 micrometers, but not to the fine mode effective radius. The Angstrom exponent is also known to vary with wavelength, which is commonly referred to as curvature; we show how the spectral curvature can provide additional information about aerosol size distributions for intermediate values of the Angstrom exponent. Curvature also has a significant effect on the conclusions that can be drawn about two-wavelength Angstrom exponents; long wavelengths (0.67, 0.87 micrometers) are sensitive to fine mode volume fraction of aerosols but not fine mode effective radius, while short wavelengths (0.38, 0.44 micrometers) are sensitive to the fine mode effective radius but not the fine mode volume fraction.

Schuster, Gregory L.↗

NASA NTRS1993

Buckling analysis of laminated thin shells in a hot environment

Results are presented of parametric studies to assess the effects of various parameters on the buckling behavior of angle-ply, laminated thin shells in a hot environment. These results were obtained by using a three-dimensional finite element analysis. An angle-ply, laminated thin shell with fiber orientation of (theta/-theta)(sub 2) was subjected to compressive mechanical loads. The laminated thin shell had a cylindrical geometry. The laminate contained T300 graphite fibers embedded in an intermediate-modulus, high-strength (IMHS) matrix. The fiber volume fraction was 55 percent and the moisture content was 2 percent. The residual stresses induced into the laminate structure during the curing were taken into account. Parametric studies were performed to examine the effect on the critical buckling load of the following parameters: cylinder length and thickness, internal hydrostatic pressure, different ply thicknesses, different temperature profiles through the thickness of the structure, and different lay up configurations and fiber volume fractions. In conjunction with these parameters the ply orientation was varied from 0 deg to 90 deg. Seven ply angles were examined: 0 deg, 15 deg, 30 deg, 45 deg, 60 deg, 75 deg, and 90 deg. The results show that the ply angle theta and the laminate thickness had significant effects on the critical buckling load. The fiber volume fraction, the fiber orientations, and the internal hydrostatic pressure had important effects on the critical buckling load. The cylinder length had a moderate influence on the buckling load. The thin shell with (theta/-theta)(sub 2) or (theta/-theta)(sub s) angle-ply laminate had better buckling-load performance than the thin shell with (theta)(sub 4) angle-ply laminate. The temperature profiles through the laminate thickness and various laminates with the different ply thicknesses has insignificant effects on the buckling behavior of the thin shells.

Gotsis, Pascal K.↗

NASA NTRS1988

Quantitative non-destructive evaluation of porous composite materials based on ultrasonic wave propagation

Two complementary ultrasonic techniques for characterizing porosity in fiber-reinforced composite laminates are evaluated. Five uniaxial graphite-fiber/epoxy-matrix composites having a range of 1 to 8 percent volume fraction of solid glass inclusions to model porosity were investigated. In one technique, signal loss was measured in transmission mode and slope of attenuation, obtained from the first order coefficient of a two-parameter polynomial fit about the center frequency of the useful bandwidth, was used as the ultrasonic parameter to characterize the porosity. The results of these transmission mode measurements displayed a good correlation between the volume fraction of porosity and the slope of attenuation. Integrated polar backscatter was used as a second ultrasonic parameter for the characterization of the porosity in these samples. A single transducer insonified the samples and measured the resulting backscatter at a polar angle of 30 deg with respect to the normal of the sample surface with the azimuthal angles centered at 0 deg with respect to the fiber orientation (i.e., along the fibers). Integrated polar backscatter also displayed good correlation with the volume fraction of porosity.

Miller, James G.↗