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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

The Development and Prevention of Channel Segregation During Alloy Solidification

During alloy solidification, interdendritic microsegregation causes density differences between entrapped liquid and bulk liquid which provides a driving force for convection. One of the consequences of this effect is the formation of long, nearly vertical liquid channels, rich in solute, flowing through the solid-liquid mushy zone somewhat as a river and tributary system. In ingot castings where the heat flow is vertically downwards and the solute less dense than the solute the convective flow is antiparallel with the flow caused by contraction on freezing. Identification of the mechanisms involved in these two problems is discussed. It is known that certain types of bulk liquid movements can inhibit channel development and the mechanism by which they do so are examined.

Hellawell, A.↗
NASA NTRS1985

Experimental determination of systems suitable for study as monotectic binary metallic alloy solidification models

Transparent binary metallic alloy solidification models are important in attempts to understand the processes causing liquid-liquid and solid-liquid phase transformations in metallic alloy systems. These models permit visual observation of the phase transformation and the processes proceding solidification. The number of these transparent monotectic binary models needs to be expanded to distinguish between the unique and general phenomena observed. The expansion of the number of accurately determined monotectic phase diagrams of model systems, and contribution to a data base for eventual use with UNIFAC group contribution methods is examined.

Smith, J. E., Jr.↗
NASA NTRS2000

Modeling of a Non-Dilute Alloy Solidification Under Terrestrial and Microgravity Conditions

A general finite element model of non-dilute alloy solidification was used to simulate growth of HgCdTe from the melt. 2-D and 3-D models with and without Oberbeck-Boussinesq (O-B) approximation were used. Verification of the 3-D model was based on experimental data. The location and the shape of the interface were determined using melting temperatures obtained from the HgCdTe liquidus curve. Double-diffusive convection in the melt is caused by radial temperature gradients and by rejection at the solid-melt interface of the heavier HgTe-rich solute. Because of these complicating factors, dimensional rather than non-dimensional modeling was performed. Models based on complete set of Navier-Stokes equations for compressible media are superior to the O-B approximation in microgravity, because they provide more accurate estimation of convection.

Bune, Andris V.↗
NASA NTRS1983

Determination of Systems Suitable for Study as Monotectic Binary Metallic Alloy Solidification Models

Succinonitrile-water and diethylene glycol-ethyl salicylate are two transparent systems which have been studied as monotectic binary metallic alloy solidification models. Being transparent, these systems allow for the direct observations of phase transformations and solidification reactions. The objective was to develop a screening technique to find systems of interest and then experimentally measure those systems. The succinonitrile-water system was used to check the procedures. To simulate the phase diagram of the system, two computer programs which determine solid-liquid and liquid-liquid equilibria were obtained. These programs use the UNIFAC method to determine activity coefficients and together with several other programs were used to predict the phase diagram. An experimental apparatus was developed and the succinonitrile-water phase diagram measured. The diagram was compared to both the simulation and literature data. Substantial differences were found in the comparisons which serve to demonstrate the need for this procedure.

Smith, J. E., Jr.↗
NASA NTRS1992

A study of aluminum-lithium alloy solidification using acoustic emission techniques

Physical phenomena associated with the solidification of an aluminum lithium alloy was characterized using acoustic emission (AE) techniques. It is shown that repeatable patterns of AE activity may be correlated to microstructural changes that occur during solidification. The influence of the experimental system on generated signals was examined in the time and frequency domains. The analysis was used to show how an AE signal from solidifying aluminum is changed by each component in the detection system to produce a complex waveform. Conventional AE analysis has shown that a period of high AE activity occurs in pure aluminum, an Al-Cu alloy, and the Al-Li alloy, as the last fraction of solid forms. A model attributes this to the internal stresses of grain boundary formation. An additional period of activity occurs as the last fraction of solid forms, but only in the two alloys. A model attributes this to the formation of interdendritic porosity which was not present in the pure aluminum. The AE waveforms were dominated by resonant effects of the waveguide and the transducer.

Henkel, Daniel P.↗
NASA NTRS2001

Dendritic Alloy Solidification Experiment (DASE)

A space experiment, and supporting ground-based research, is proposed to study the microstructural evolution in free dendritic growth from a supercooled melt of the transparent model alloy succinonitrile-acetone (SCN-ACE). The research is relevant to equiaxed solidification of metal alloy castings. The microgravity experiment will establish a benchmark for testing of equiaxed dendritic growth theories, scaling laws, and models in the presence of purely diffusive, coupled heat and solute transport, without the complicating influences of melt convection. The specific objectives are to: determine the selection of the dendrite tip operating state, i.e. the growth velocity and tip radius, for free dendritic growth of succinonitrile-acetone alloys; determine the growth morphology and sidebranching behavior for freely grown alloy dendrites; determine the effects of the thermal/solutal interactions in the growth of an assemblage of equiaxed alloy crystals; determine the effects of melt convection on the free growth of alloy dendrites; measure the surface tension anisotropy strength of succinon itrile -acetone alloys establish a theoretical and modeling framework for the experiments. Microgravity experiments on equiaxed dendritic growth of alloy dendrites have not been performed in the past. The proposed experiment builds on the Isothermal Dendritic Growth Experiment (IDGE) of Glicksman and coworkers, which focused on the steady growth of a single crystal from pure supercooled melts (succinonitrile and pivalic acid). It also extends the Equiaxed Dendritic Solidification Experiment (EDSE) of the present investigators, which is concerned with the interactions and transients arising in the growth of an assemblage of equiaxed crystals (succinonitrile). However, these experiments with pure substances are not able to address the issues related to coupled heat and solute transport in growth of alloy dendrites.

Beckermann, C.↗
NASA NTRS1999

In-Situ Monitoring of a Bismuth-Tin Alloy Solidification Using MEPHISTO

Experiments were carried out to study the morphological stability of Bi- 1 atomic % Sn alloys using the MEPHISTO directional solidification apparatus aboard Space Shuttle Columbia (STS-87, launched Nov. 19, 1997) and in ground-based studies. The Seebeck signal and temperature measurements indicate that convection was significant for ground-based studies. In the space-based experiments, interface breakdown was observed at growth velocities of 6.7, 27, and 40 microns/sec, but not at 1.8 and 3.3 microns/sec.

Abbaschian, Reza↗
NASA NTRS1992

Observation of alloy solidification using high-speed video

A high-speed video instrumentation system was used to observe solidification of undercooled Ti-51 at. pct Al. The camera system developed by Battelle is capable of operation at rates up to 12,000 frames per second. The system digitizes and stores video images acquired by a 64 x 64 pixel silicon photodiode array. In a joint effort with Vanderbilt University the camera was used to observe three transformations of the undercooled alloys, using containerless processing by electromagnetic levitation. The first was solidification where nucleation was induced at an undercooling of 9 percent Tl, where Tl is the liquidus temperature of the alloy, and the second was solidification where nucleation was spontaneous at an undercooling of 15 percent Tl. The third event was a solid-state nucleation and growth transformation following the solidification at an undercooling of 15 percent Tl.

Bassler, B. T.↗
NASA NTRS2010

Linear Stability of Binary Alloy Solidification for Unsteady Growth Rates

An extension of the Mullins and Sekerka (MS) linear stability analysis to the unsteady growth rate case is considered for dilute binary alloys. In particular, the stability of the planar interface during the initial solidification transient is studied in detail numerically. The rapid solidification case, when the system is traversing through the unstable region defined by the MS criterion, has also been treated. It has been observed that the onset of instability is quite accurately defined by the "quasi-stationary MS criterion", when the growth rate and other process parameters are taken as constants at a particular time of the growth process. A singular behavior of the governing equations for the perturbed quantities at the constitutional supercooling demarcation line has been observed. However, when the solidification process, during its transient, crosses this demarcation line, a planar interface is stable according to the linear analysis performed.

Mazuruk, K.↗
NASA NTRS1984

The mechanisms of formation and prevention of channel segregation during alloy solidification

Using a base chilled configuration, conditions for the formation and prevention of segregation channels are studied in the ammonium chloride-water and lead-tin systems. Such channels develop when the rejected solute is less dense than the solvent and are therefore a result of density inversion, but slow (less than 5 rpm) rates of mold rotation, about axes inclined to the vertical by 20 to 30 deg, throughout the time of solidification, effectively prevent the formation or propagation of these channels. In experiments with artificially created or blocked channels, a simultaneous solute plume in the bulk liquid must be present in order for a channel to develop. The results indicate that channels originate not within the dendritic array, but immediately ahead of the growth front as a result of perturbation from the less dense boundary layer into the bulk liquid. The effect of mold movement is to translate laterally the bulk liquid relative to the growth front so that perturbations are sheared off. The nature of the liquid movement is considered and shown to be a function of the mold dimensions.

Hellawell, A.↗
NASA NTRS1986

Fundamentals of Alloy Solidification

Potential benefits of microgravity processing discussed. Symposium held at Lewis Research Center in September of 1984 on subject of microgravity and some basic metallurgical factors involved in production of metals. General metallurgical areas of interest were metal solidification and processing. Five specific areas covered included undercooling of liquids, porosity, microstructure, solidification, and segregation. Theme of symposium: Possible benefits of microgravity processing and beneficial effects on industry processing. Information readily lends itself to inclusion in educational programs at college level.

Harf, F.↗
NASA NTRS1992

The influence of processing parameters on microstructural development of low-weight-percent primary, pro-eutectic, dendritic alloys during directional solidification

Alloy compositions centering about Sn- 5 to 15 wt pct Al and Pb- 4 to 20 wt pct Cu have been directionally solidified as a function of growth rate and orientation with respect to earth's gravity vector. The effect of these processing variables on macrosegregation is presented, and the consequence of a structural transition from primary columnar to equiaxed dendritic growth is examined. Effects detrimental to microstructure and attributed to density variations are shown to be minimized by a novel processing technique. In view of the ground-based results, some considerations follow regarding what might be gained by solidifying these alloys in a microgravity environment.

Grugel, R. N.↗
NASA NTRS1997

Transport Phenomena During Equiaxed Solidification of Alloys

Recent progress in modeling of transport phenomena during dendritic alloy solidification is reviewed. Starting from the basic theorems of volume averaging, a general multiphase modeling framework is outlined. This framework allows for the incorporation of a variety of microscale phenomena in the macroscopic transport equations. For the case of diffusion dominated solidification, a simplified set of model equations is examined in detail and validated through comparisons with numerous experimental data for both columnar and equiaxed dendritic growth. This provides a critical assessment of the various model assumptions. Models that include melt flow and solid phase transport are also discussed, although their validation is still at an early stage. Several numerical results are presented that illustrate some of the profound effects of convective transport on the final compositional and structural characteristics of a solidified part. Important issues that deserve continuing attention are identified.

Beckermann, C.↗