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13 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

A Design of Experiments Approach Defining the Relationships Between Processing and Microstructure for Ti-6Al-4V

A study was conducted to evaluate the relative significance of input parameters on Ti- 6Al-4V deposits produced by an electron beam free form fabrication process under development at the NASA Langley Research Center. Five input parameters where chosen (beam voltage, beam current, translation speed, wire feed rate, and beam focus), and a design of experiments (DOE) approach was used to develop a set of 16 experiments to evaluate the relative importance of these parameters on the resulting deposits. Both single-bead and multi-bead stacks were fabricated using 16 combinations, and the resulting heights and widths of the stack deposits were measured. The resulting microstructures were also characterized to determine the impact of these parameters on the size of the melt pool and heat affected zone. The relative importance of each input parameter on the height and width of the multi-bead stacks will be discussed. .

Wallace, Terryl A.↗
NASA NTRSDate not supplied

Influence of Thermophysical Property Variability on Thermal Predictions of Ti-6Al-4V

The additive manufacturing (AM) industry has experienced rapid growth in recent decades as industrial interest in the process has grown. Because of this, there are many groups interested in simulations of the AM process. However, the influence of thermophysical property variability on the melt pool geometry during processing of various AM alloys is unclear. The goal of my work at NASA Langley Research Center (LaRC) was to characterize this influence on Ti-6Al-4V during AM processing alongside developing a tool to enable equivalent studies on other AM materials. To facilitate this process, a database tool was developed to contain and organize thermophysical data previously reported by primary sources. The specific thermophysical properties of interest for this study were density, specific heat capacity, and conductivity. Thermal diffusivity was calculated using the other three properties. This data was then fit with a Gaussian distribution and then randomly sampled from using Monte Carlo random value sampling. Using the Rosenthal equation, this sample data was used to simulate the temperature field during additive manufacturing and extract the melt pool geometry. Specifically, the melt pool’s length, width, and depth. This process was repeated an arbitrary number of times, with the default being 1000. Once this information was obtained, histograms were made showing the distributions of the sizes of the melt pool’s length, width, and depth. Representative statistical metrics of the distributions were calculated (mean, standard deviation, and coefficient of variance). This work found that at the simulated processing values, the melt pool’s width and depth had a 5.7% variation while the length had a 3.2% variation. Additionally, a tool was constructed to graph a thermal color map representation of the melt pool for specific, arbitrary values of density, specific heat, and conductivity. This tool allowed for more efficient plotting of individual queries of the thermophysical properties. The results that were observed in the research were that values reported in literature vary and this variance can have a significant impact on the simulation. Predictions of the melt pool’s dimensions show that length has a standard deviation of approximately 6 μm, width has a standard deviation of approximately 5 μm, and depth can vary by approximately 3 μm. Considering the mean sizes of length, width, and depth are 185 μm, 88 μm, and 44 μm respectively, such a deviation is significant. This shows that depth, for example, could be more than 10% larger or smaller than expected. This demonstrates that variability in the reported thermophysical properties are not negligible and should be expected to have an influence on the results of the laser powder bed fusion additive manufacturing process. When simulating this process in the future, measures should be taken to account for this discrepancy and the uncertainty involved

Justin Martin↗
NASA NTRS2004

Starting Conditions for Hydrothermal Systems Underneath Martian Craters: Hydrocode Modeling

Mars is the most Earth-like of the Solar System s planets, and the first place to look for any sign of present or past extraterrestrial life. Its surface shows many features indicative of the presence of surface and sub-surface water, while impact cratering and volcanism have provided temporary and local surface heat sources throughout Mars geologic history. Impact craters are widely used ubiquitous indicators for the presence of sub-surface water or ice on Mars. In particular, the presence of significant amounts of ground ice or water would cause impact-induced hydrothermal alteration at Martian impact sites. The realization that hydrothermal systems are possible sites for the origin and early evolution of life on Earth has given rise to the hypothesis that hydrothermal systems may have had the same role on Mars. Rough estimates of the heat generated in impact events have been based on scaling relations, or thermal data based on terrestrial impacts on crystalline basements. Preliminary studies also suggest that melt sheets and target uplift are equally important heat sources for the development of a hydrothermal system, while its lifetime depends on the volume and cooling rate of the heat source, as well as the permeability of the host rocks. We present initial results of two-dimensional (2D) and three-dimensional (3D) simulations of impacts on Mars aimed at constraining the initial conditions for modeling the onset and evolution of a hydrothermal system on the red planet. Simulations of the early stages of impact cratering provide an estimate of the amount of shock melting and the pressure-temperature distribution in the target caused by various impacts on the Martian surface. Modeling of the late stage of crater collapse is necessary to characterize the final thermal state of the target, including crater uplift, and distribution of the heated target material (including the melt pool) and hot ejecta around the crater.

Pierazzo, E.↗
NASA NTRS1984

Characterization of macrosegregation in ESR IN-718

Aspects of macrosegregation theory, such as dendrite arm spacing, pool profile and mushy zone depth are beneficial to developing consumable melting process for Ion Nickel IN-718, Electro-Slag Refining, especially ESR. Aspects of microsegregation theory, such as correlation of dendrite arm spacing with heat transfer mechanisms and local solidification time, are used to minimize remnant dendritism in both ESR and Vacuum Arc Remelting VAR IN-718. Specifically, ESR IN-718 must be optimized by developing practices which maximize ingot cooling rate and minimize the steepness of the solidus and liquidus isotherms. The knowledge concerning macrosegregation in consumable melted IN-718 is in the form of correlations. Since the isotherm steepness is undoubtedly involved, investigations which include a microgravity environment might separate microsegregation effects from macrosegregation effects. Accounting for the effects of gravity and density differences between the metal pool and the interdendritic fluid, in combination with the pool and mushy zone profiles, can lead to improved melting solidification practices for IN-718, and allow prediction of macrosegregation tendency to be incorporated into high temperature alloy design.

Domingue, J. A.↗
NASA NTRS2017

Relationship of Powder Feedstock Variability to Microstructure and Defects in Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer by layer. For selective laser melted (SLM) Alloy 718, the powders that are available off-the-shelf are in the 10-45 or 15-45 micron size range. A comprehensive investigation of sixteen powders from these typical ranges and two off-nominal-sized powders is underway to gain insight into the impact of feedstock on processing, durability and performance of 718 SLM space-flight hardware. This talk emphasizes an aspect of this work: the impact of powder variability on the microstructure and defects observed in the as-fabricated and full heated material, where lab-scale components were built using vendor recommended parameters. These typical powders exhibit variation in composition, percentage of fines, roughness, morphology and particle size distribution. How these differences relate to the melt-pool size, porosity, grain structure, precipitate distributions, and inclusion content will be presented and discussed in context of build quality and powder acceptance.

Characterization↗
NASA NTRSDate not supplied

Zircon (U-Th)/He Impact Crater Thermochronometry and the Effects of Shock Microstructures on Helium Diffusion Kinetics

Accurate and precise age determination of impact cratering events remains challenging and often contentious; less than half of all known craters are regarded as accurately and precisely dated. Zircon (U-Th)/He (ZHe) dating of impactites can be employed to date medium to large impact structures as ZHe ages can be fully reset in minutes at T >1000°C, a plausible scenario in the central melt pool. In contrast, complete resetting of ZHe at 200-300°C, encountered near the crater margins or due to post-impact hydrothermal overprinting, may take >103-6 years. To test the reliability of ZHe impact dating, we have quantified the effects of shock-induced microstructures on helium diffusion kinetics in well-characterized variably shocked zircon. We investigated samples from two impact structures, the Chicxulub multi-ring crater and Ries complex crater, to compare diffusion kinetics from structures with different size, age, and hydrothermal system longevity. Shock microstructures were characterized by backscattered-electron imaging prior to determining the He diffusion kinetics by prograde and retrograde fractional-release experiments via light-bulb furnace with incremental step-heating (10°C) from 300°C to 600°C. Next, we examine the internal interconnectivity and sizes of the diffusion domains by EBSD. While we found that zircon with few shock microstructures exhibited no marked deviation from helium diffusion kinetics of undamaged zircon, zircon grains with planar microstructures and granular textures are characterized by a dramatic decrease in helium retentivity due to the reduction in the effective domain size and the introduction of interconnected fast diffusion pathways. A subset of grains were ZHe dated and showed that less deformed grains yielded a weighted mean age within error of the accepted impact ages, while the grains with planar microstructures or granular textures gave systematically younger ages. These new diffusion data and ZHe ages demonstrate that highly shocked grains are unsuitable for ZHe impact crater dating. Therefore, detailed characterization of impact-induced microstructures is critical for determining accurate ZHe impact ages and offers the possibility of investigating post-impact hydrothermal circulation.

Zircon↗
NASA NTRS2001

Magnetic Damping of g-Jitter Induced Double-Diffusive Convection

This paper describes a numerical study of the g-jitter driven double diffusive convective flows, thermal and concentration distributions in binary alloy melt systems subject to an external magnetic field. The study is based on the finite element solution of transient magnetohydrodynamic equations governing the momentum, thermal and solutal transport in the melt pool. Numerical simulations are conducted using the synthesized single- and multi- frequency g-jitter as well as the real g-jitter data taken during space flights with or without an applied magnetic field. It is found that for the conditions studied, the main melt flow follows approximately a lineal- superposition of velocity components induced by individual g-jitter components, regardless of whether a magnetic field exists or not. The flow field is characterized by a recirculating double diffusive convection loop oscillating in time with a defined frequency equal to that of the driving g-jitter force. An applied magnetic field has little effect on the oscillating recirculating pattern, except around the moment in time when the flow reverses its direction. The field has no effect on the oscillation period, but it changes the phase angle. It is very effective in suppressing the flow intensity and produces a notable reduction of the solutal striation and time fluctuations in the melt. For a given magnetic field strength, the magnetic damping effect is more pronounced on the velocity associated with the largest g-jitter component present and/or the g-jitter spiking peaks. A stronger magnetic field is more effective in suppressing the melt convection and also is more helpful in bringing the convection in phase with the g-jitter driving force. The applied field is particularly useful in suppressing the effect of real g-jitter spikes on both flow and solutal distributions. With appropriately selected magnetic fields, the convective flows caused by g-jitter can be reduced sufficiently and diffusion dominant. solutal transport in the melt is possible.

Shu, Y.↗
NASA NTRSDate not supplied

Mars Water Well Performance: Experimental Heat Transfer Results Supporting Simulations

Favorable indications of massive quantities of water on Mars have initiated studies of potential changes to human Mars missions. Using a technique known as a Rodriguez Well to melt the ice, store the resulting water in a subsurface ice cavity until needed, and then pump water to the surface for use is one potential means to effect these changes. A computer simulation of the Rodriguez Well in a terrestrial environment is one of the engineering tools being used to characterize the performance of this type of well on Mars. An experiment at the NASA Johnson Space Center gathered data for evaporation rates and convective heat transfer at Mars surface conditions so that this computer simulation could be appropriately modified to predict performance on Mars. Tests have indicated that a pool of water can be maintained at 1°C to 2° C while at Mars surface temperatures and pressures. Preliminary results for evaporation rates and convective heat transfer have been determined and are presented.

Stephen J Hoffman↗
NASA NTRS2002

Major Element Analysis of the Target Rocks at Meteor Crater, Arizona

We collected approximately 400 rock chips in continuous vertical profile at Meteor Crater, Arizona, representing, from bottom to top, the Coconino, Toroweap, Kaibab, and Moenkopi Formations to support ongoing compositional analyses of the impact melts and their stratigraphic source depth(s) and other studies at Meteor Crater that depend on the composition of the target rocks. These rock chips were subsequently pooled into 23 samples for compositional analysis by XRF (x ray fluorescence) methods, each sample reflecting a specific stratigraphic "subsection" approximately 5-10 in thick. We determined the modal abundance of quartz, dolomite, and calcite for the entire Kaibab Formation at vertical resolutions of 1-2 meters. The Coconino Formation composes the lower half of the crater cavity. It is an exceptionally pure sandstone. The Toroweap is only two inches thick and compositionally similar to Coconino, therefore, it is not a good compositional marker horizon. The Kaibab Formation is approximately 80 in thick. XRD (x ray diffraction) studies show that the Kaibab Formation is dominated by dolomite and quartz, albeit in highly variable proportions; calcite is a minor phase at best. The Kaibab at Meteor Crater is therefore a sandy dolomite rather than a limestone, consistent with pronounced facies changes in the Permian of SE Arizona over short vertical and horizontal distances. The Moenkopi forms the 12 in thick cap rock and has the highest Al2O3 and FeO concentrations of all target rocks. With several examples, we illustrate how this systematic compositional and modal characterization of the target ideologies may contribute to an understanding of Meteor Crater, such as the depth of its melt zone, and to impact cratering in general, such as the liberation of CO2 from shocked carbonates.

See, Thomas H.↗
NASA NTRS2020

Experimental Heat Transfer Supporting Simulated Water Well Performance on Mars

Favorable indications of massive quantities of water on Mars have initiated studies of potential changes to human Mars missions. Using a technique known as a Rodriguez Well to melt the ice, store the resulting water in a subsurface ice cavity until needed, and then pump water to the surface for use is one potential means to effect these changes. A computer simulation of the Rodriguez Well in a terrestrial environment is one of the engineering tools being used to characterize the performance of this type of well on Mars. An experiment at the NASA Johnson Space Center is gathering data for convective heat transfer and evaporation rates at Mars surface conditions so that this computer simulation can be properly modified to predict performance on Mars. While quantitative results await processing, tests have indicated that a pool of water can be maintained at 1°C to 2° C while at Mars surface temperatures and pressures.

Hoffman, Stephen J.↗
NASA NTRSDate not supplied

Mars Water Well Performance: Experimental Heat Transfer Results Supporting Simulations

Favorable indications of massive quantities of water on Mars have initiated studies of potential changes to human Mars missions. Using a technique known as a Rodriguez Well to melt the ice, store the resulting water in a subsurface ice cavity until needed, and then pump water to the surface for use is one potential means to effect these changes. A computer simulation of the Rodriguez Well in a terrestrial environment is one of the engineering tools being used to characterize the performance of this type of well on Mars. An experiment at the NASA Johnson Space Center is gathering data for convective heat transfer and evaporation rates at Mars surface conditions so that this computer simulation can be properly modified to predict performance on Mars. While quantitative results await processing, tests have indicated that a pool of water can be maintained at 1°C to 2° C while at Mars surface temperatures and pressures.

Mars↗
NASA NTRS1978

Compositional-petrographic investigation of pristine nonmare rocks

Twenty-six highlands rocks and clasts are characterized petrographically and by determinations of major and trace elements, including key incompatibles and siderophiles. Most samples were selected in the hope that they would prove to be pristine, i.e., unremelted, monomict products of endogenous lunar magmatism. About 3/5 are almost certainly pristine, while about 1/4 are definitely non-pristine, and the remainder await further study before pristinity may be either proven or disproven. All of the major conclusions of Warren and Wasson (1977) about the significance of pristine nonmare rocks and the nature of the lunar crust still appear correct. Probably none, or virtually none, of the samples possessing the attributes by which 'pristinity' is judged formed as 'secondary differentiates' in giant impact melt pools, as Delano and Ringwood (1978) propose. Those which possess markedly plutonic textures (e.g., 62236) almost certainly did not.

Warren, P. H.↗
NASA NTRS1994

Compositional Variation in Apollo 16 Impact-Melt Breccias and Inferences for the Geology and Bombardment History of the Central Highlands of the Moon

High-precision data for the concentrations of a number of lithophile and siderophile elements were obtained on multiple subsamples from 109 impact-melt rocks and breccias (mostly crystalline) from the Apollo 16 site. Compositions of nearly all Apollo 16 melt rocks fall on one of two trends of increasing Sm concentration with increasing Sc concentration. The Eastern trend (lower Sm/Sc, Mg/Fe, and Sm/Yb ratios) consists of compositional groups 3 and 4 of previous classification schemes. These melt rocks are feldspathic, poor in incompatible and siderophile elements, and appear to have provenance in the Descartes formation to the east of the site. The Western trend (higher Sm/Sc. Mg/Fe, and Sm/ Yb ratios) consists of compositional groups 1 and 2. These relatively mafic, KREEP-bearing breccias are a major component (approx.35%) of the Cayley plains west of the site and are unusual, compared to otherwise similar melt breccias from other sites, in having high concentrations of Fe-Ni metal ( 1-2 %). The metal is the carrier of the low-Ir/Au (approx. 0.3 x chondritic) siderophile-element signature that is characteristic of the Apollo 16 site. Four compositionally distinct groups (1M, 1F, 2DB, and 2NR) of Western-trend melt breccias occur that are each represented by at least six samples. Compositional group 1 or previous classification schemes (the 'poikilitic' or 'LKFM' melt breccias) can be subdivided into two groups. Group 1M (represented by six samples, including 60315) is characterized by lower Al2O3 concentrations, higher MgO and alkali concentrations, and higher Mg/Fe and Cr/Sc ratios than group 1F (represented by fifteen samples, including 65015). Group 1M also has siderophile-element concentrations averaging about twice those of group lF and Ir/Au and Ir/Ni ratios that are even lower than those of other Western-trend melt rocks (Ir/Au = 0.24 +/- 0.03. CI-normalized). At the mafic extreme of group 2 ('VHA' melt breccias), the melt lithology occurring as clasts in feldspathic fragmental breccias from North Ray crater (group 2NR) is compositionally distinct from the melt lithology ofdimict breccias from the Cayley plains (group 2DB) in having higher concentrations of Sc, Cr, and heavy rare earth elements and lower concentrations of siderophile elements. The distinct siderophile-element signature (high absolute abundances, low Ir/Au ratio) suggest that the four groups ofmafic melt breccia are all somehow related. Ratios ofsome lithophile elements also suggest that they are more closely related to each other than then, are to melt breccias from other Apoll sites. However, none of the breccia compositions can be related to any of the others by any simple process of igneous fractionation or mixing involving common lunar materials. Thus, the origin of the four groups of mafic melt breccia is enigmatic. If they were produced in only one or two impacts, then a mechanism exists for generating regimes of impact-melt breccia in a single impact that are substantially different from each other in composition. For various reasons, including the problem of delivering large volumes of four different types of melt to the Apollo 16 site, it is unlikely that any of these breccias were produced in basin-forming impacts. If they were produced in as many as four crater-forming impacts, then the unusual siderophile-element signature is difficult to explain. Possible explanations are (1) the four groups of melt breccia all contain metal from a single, earlier impact, (2) they were each formed by related metal-rich meteoroids, or (3) some common postimpact process has resulted in metal of similar composition in each of four melt pools. Within a compositional group, most intrasample and intersample variation in lithophile element concentrations is caused by differences among samples in the proportion of a component of normative anorthosite or noritic anorthosite. In most cases, this compositional variation probably reflects variation in clast abundance. For group 2DB (and probably 2NR), differences in abundance of a component of ferroan anorthosite (estimated Al2O3 approx. 32%) accounts for the compositional variation. For groups 1M and 1F, the anorthositic component is more mafic (estimated Al203 approx. 26%). Some group-2 samples may be related by a troctolitic component of varying abundance.

Korotev, Randy L.↗