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Results for “melting behavior”

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
DOE OSTI2019

Effect of sucrose on foaming and melting behavior of a low-activity waste melter feed

Reductants, such as sucrose, are added to nuclear waste melter feeds containing high fractions of nitrates and nitrites to reduce excessive foaming during feed-to-glass conversion and to decrease sulfate segregation and increase technetium retention. The sucrose effect on foaming and melting reactions during the conversion was examined using the feed volume expansion, thermogravimetric analysis, evolved gas analysis, X-ray diffraction, and scanning electron microscopy with energy dispersive X-ray spectrometry. Different sucrose additions were used to vary the carbon to nitrogen (C/N) ratio in the melter feed. As C/N ratio increased, the extent of foaming decreased and N2/NO ratio increased in the gas phase evolved. Significant foam suppression, rapid gas release at approximately 250°C, and reduction of transition metal oxides were observed at C/N > 1.1.

Appel, Connor J.↗
DOE OSTI2024

The Melting Behavior of Hydrogen Direct Reduced Iron in Molten Steel and Slag: An Integrated Computational and Experimental Study

Direct reduced iron (DRI) and hot briquetted iron (HBI) are essential feedstocks for tramp element control in the electric arc furnace (EAF). Due to greenhouse gas (GHG) concerns related to CO2 emissions, hydrogen as a substitute for natural gas and a reductant in DRI production is being widely explored to reduce GHG emissions in ironmaking. This study examines the melting behavior of hydrogen DRI (H-DRI) pellets in the EAF containing low-carbon (0.1 wt.%) molten steel and molten slag. A computational heat transfer model was developed to predict the melting behavior of H-DRI pellets. To validate the model, a set of experimental laboratory simulations was conducted by immersing H-DRI in a molten steel bath and slag. The temperature history at the center of the pellet during melting and the shell thickness at different melting stages were utilized to validate the model. The simulation results agree with the experimental measurements of steel balls and H-DRI in different metallic molten steel and slag baths.

Materials Science↗
DOE OSTI2022

Melting Behavior of Conventional and Hydrogen-Reduced DRI in a Simulated EAF Steel Bath

The melting behavior of carbon-free direct reduced iron (DRI) produced by hydrogen reduction has been investigated in a simulated electric arc furnace (EAF) melting environment. A testing apparatus was created to document the melting rates under various bath conditions in slag and steel. This investigation is specific to pellets melted in a steel bath. A model was developed to simulate the shell growth and melting rate of a non-reactive DRI pellet in molten steel. Data acquired from preliminary experiments are utilized to validate the model. This investigation sheds light on the potential effects of melting hydrogen-reduced DRI in the EAF.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Reproduction of melting behavior for vitrified hillforts based on amphibolite, granite, and basalt lithologies

Abstract European Bronze and Iron Age vitrified hillforts have been known since the 1700s, but archaeological interpretations regarding their function and use are still debated. We carried out a series of experiments to constrain conditions that led to the vitrification of the inner wall rocks in the hillfort at Broborg, Sweden. Potential source rocks were collected locally and heat treated in the laboratory, varying maximum temperature, cooling rate, and starting particle size. Crystalline and amorphous phases were quantified using X-ray diffraction both in situ, during heating and cooling, and ex situ, after heating and quenching. Textures, phases, and glass compositions obtained were compared with those for rock samples from the vitrified part of the wall, as well as with equilibrium crystallization calculations. ‘Dark glass’ and its associated minerals formed from amphibolite or dolerite rocks melted at 1000–1200 °C under reducing atmosphere then slow cooled. ‘Clear glass’ formed from non-equilibrium partial melting of feldspar in granitoid rocks. This study aids archaeological forensic investigation of vitrified hillforts and interpretation of source rock material by mapping mineralogical changes and glass production under various heating conditions.

42 ENGINEERING↗
DOE OSTI2024

Ambient melting behavior of stoichiometric uranium oxides

As UO 2 is easily oxidized during the nuclear fuel cycle it is important to have a detailed understanding of the structures and properties of the oxidation products. Experimental work over the years has revealed many stable uranium oxides including UO 2 , U 4 O 9 (UO 2.25 ), U 3 O 7 (UO 2.33 ), U 2 O 5 (UO 2.5 ), U 3 O 8 (UO 2.67 ), and UO 3 , all with a number of different polymorphs. These oxides are broadly split into two categories, fluorite-based structures with stoichiometries in the range of UO 2 to UO 2.5 and less dense layered-type structures with stoichiometries in the range of UO 2.5 to UO 3 . While UO 2 is well characterized, both experimentally and computationally, there is a paucity of data concerning higher stoichiometry oxides in the literature. In this work we determine the ambient melting points of all the six stoichiometric uranium oxides listed above and compare them to the available experimental and/or theoretical data. We demonstrate that a family of the six ambient melting points map out a solid-liquid transition boundary consistent with the high-temperature portion of the phase diagram of uranium-oxygen system suggested by Babelot et al.

Burakovsky, Leonid↗
DOE OSTI2021

Iron-rich microstructure records of high temperature multi-component silicate melt behavior in nuclear fallout

Above-ground nuclear explosions that interact with the surface of the earth entrain materials from the surrounding environment, influencing the resulting physical and chemical evolution of the fireball, which can affect the final chemical phase and mobility of hazardous radionuclides that are dispersed in the environment as fallout particles. The interaction of iron with a nuclear explosion is of specific interest due to the potential for iron to act as a redox buffer and because of the likelihood of significant masses of metals to be present in urban environments. We investigated fallout from a historic surface interacting nuclear explosion conducted on a steel tower and report the discovery of widespread and diverse iron-rich micro-structures preserved within the samples, including crystalline dendrites and micron-scale iron-rich spheres with liquid immiscibility textures. We assert these micro-structures reflect local redox conditions and cooling rates and can inform interpretation of high temperature events, enabling new insights into fireball condensation physics and chemistry when metals from the local environment (i.e. structural steel) are vaporized or entrained. Finally, these observations also significantly expand the availability of silicate immiscibility datasets applicable to rapidly quenched systems such as meteorite impact melt glass.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2024

Assessment of Readout Techniques for Passive Monitors

This fiscal year (FY) 2023 report on passive temperature sensors covers two main objectives: to demonstrate that the optical dilatometer can successfully process disc shaped silicon carbide (SiC) temperature monitors (TMs), and to demonstrate proof of concept for using the capacitance readout method to read printed melt wires. The SiC objective was successfully met by annealing and analyzing, via optical dilatometry, all eight 3-mm SiC discs provided by the Nuclear Science User Facilities (NSUF) Idaho State University (ISU) Nanostructured Steels for Enhanced Radiation Tolerance (N SERT) experiment, which was irradiated at Idaho National Laboratory (INL)’s Advanced Test Reactor (ATR). Per the ISU N SERT experiment, capsule 1 (KGT 3828 1 and KGT 3828-2) had a design temperature of 300°C +/- 50°C and an exposure of 2 dpa +/- 10%; capsule 2 (KGT 4600 and KGT 4609) had a design temperature of 300°C +/- 50°C and an exposure of 6 dpa +/- 10%; capsule 3 (KGT 4639 C and KGT 4639-D) had a design temperature of 500°C +/- 50°C and an exposure of 6 dpa +/- 10%; and capsule 4 (KGT 3841 3 and KGT 3841 4) had a design temperature of 500°C +/- 50°C and an exposure of 2 dpa +/- 10%. The target exposure rates, in dpa, are the neutron damage for various types of nanostructured steels. All but three SiC TMs (KGT 4600, KGT 4639 D, and KGT 3841 4) revealed averaged peak irradiation temperatures that fell within the design temperature ranges. The three SiC TMs that did not fall within the design temperatures ranges were at least 100°C below that target temperature. Furthermore, SiC TM KGT 3841 C revealed two irradiation regimes: one closer to the 300°C design temperature, and the other closer to the 500°C design temperature. Also, all the SiC TMs’ averaged peak irradiation temperatures came in anywhere between 20°C and 240°C below the irradiation temperatures predicted by the thermal models. This showed the optical dilatometry method to be a reliable and less time intensive process for determining averaged peak irradiation temperatures from passive SiC TMs such as rods and discs. Under the Advanced Sensors and Instrumentation (ASI) program in FY-23, Boise State University (BSU) proposed to demonstrate proof of concept for using a capacitance readout technique applicable to printed melt wires; however, they were stymied by the complexity of the capacitance readout method. In support of the BSU work, INL developed an additively manufactured (AM) ceramic package for encapsulating the new melt wires. Inks were synthesized at BSU that used new protocols rather than following previously established protocols implemented at INL, and testing of various temperatures was conducted at BSU to evaluate the melting behaviors of the printed melt wires. The result was that the capacitance readout technique showed promise but also created more challenges than originally anticipated. For example, the tin ink synthesized at BSU showed unusual melting behaviors that did nothing to enhance the performance of the final printed melt wire prototype in terms of the capacitance readout method. To make the proof of concept work when applied to the printed melt wires, the ASI program would need to invest further resources and time. Consequently, the program is not planning to continue this proof of concept work in FY-24, based on the progress and findings achieved in FY-23.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Deep potential development of transition-metal-rich carbides

In this study, we developed DeepPot-SE type potentials according to the High-Entropy Strategy for Cr 23 C 6 , Fe 23 C 6 , W 23 C 6 , and Mo 23 C 6 systems. Predictive molecular dynamics are then conducted according to various elastic and mechanical properties. Training dataset accuracy is confirmed both numerically and visually. Elastic constants, Poisson Ratio, and bulk modulus are determined and compared to the literature with percent errors ranging between 0.45 and 13.33%. Ground-state lattice constants yield 0.111–1.375% percent error. Linear lattice constant thermal expansion trends are found from 300 to 1500 K as expected. Melting behaviors with clear melting points are observed for each binary. Here, the Birch–Murnaghan Equation of State is suitably fit, providing additional verification of the bulk modulus calculations. Polycrystalline thermal stability is also verified for each binary potential.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Ultrafast visualization of phase transitions in nonequilibrium warm dense matter

Intense ultrafast laser excitation brings materials into highly nonequilibrium states with complex solid–liquid phase transitions. These ultrafast processes yield warm dense matter (WDM) conditions characterized by comparable thermal and Fermi energies, and strong ion–ion coupling. Here, we review recent studies employing mega-electron-volt ultrafast electron diffraction to resolve the structural dynamics of nonequilibrium WDM created by femtosecond laser heating of solids. Furthermore, for the study of warm dense gold, the results showed homogeneous melting that occurs within tens of picoseconds at absorbed energy densities of 0.4–1.4 MJ/kg. These results constrained the electron–ion coupling rate and revealed the melting sensitivity to nucleation seeds. For the study of radiation-damaged tungsten, the results showed a melting transition below the melting temperature. Molecular dynamics simulations suggested that this melting behavior is driven by vacancy defect clusters from radiation damage. These studies provided atomic-level insights into the melting behavior of materials under extreme conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Development of PBT/Recycled-PET Blends and the Influence of Using Chain Extender

In this study, PBT/recycled-PET blends were developed using a twin-screw extruder. A commercial chain extender (Joncryl ADR 4468) was also used to melt mix with PBT/recycled-PET blend systems. Firstly, Joncryl at different loadings was extruded with recycled-PET to explore the influence of branching on melt behavior and crystallization of PET. The effect of blending recycled-PET with PBT on the final properties was then explored at different blending ratios (25w/75w, 50w/50w and 75w/25w). Similar blends were subsequently prepared while incorporating chain extender. Melt behavior, phase miscibility, crystallization behavior, solid viscoelastic properties, tensile and impact properties of the blends were eventually analyzed using differential scanning calorimeter (DSC), melt flow indexer (MFI), dynamic mechanical analyzer (DMA), and tensile and Izod notched impact testing, respectively. The results showed that the addition of chain extender increased the melt viscosity of PET and at the low contents enhanced the PET’s crystallization rate. On the other hand, the blends of PBT/recycled-PET are fully miscible in the amorphous region whereas the crystalline phases are immiscible subsequent to a fast cooling. The PBT and PET molecules could also co-crystallize and be fully miscible in crystalline phases upon slow cooling of the melt. Blending recycled-PET with PBT didn’t suppress the tensile properties of PBT, however it could enhance the PBT’s ductility and reduce its impact strength. The chain extender didn’t influence the mechanical properties much. Graphical Abstract: .

36 MATERIALS SCIENCE↗
DOE OSTI2020

Confined Crystal Melting in Edgeless Poly( L -lactic acid) Crystalsomes

Polymer single crystals tend to be quasi two-dimensional (2D) lamellae and their small lateral surfaces are the starting points of lamella melting and thickening. However, the recently discovered crystalsomes, which are defined for hollow single crystal-like spherical shells, are edgeless, self-confined, and incommensurate with translational symmetry. Here, this work concerns the structure and melting behavior of these edgeless crystalsomes. Poly(l-lactic acid) crystalsomes were grown using a miniemulsion solution crystallization method. Differential scanning calorimetry and in situ wide-angle X-ray diffraction were used to follow the structural evolution of the crystalsomes upon heating. Our results demonstrated that the structure and melting behavior of crystalsomes are curvature-dependent and significantly different from their flat crystal counterpart.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Influence of alloy solidification path on melt pool behavior in additive manufacturing

Numerical models used to study transport phenomena in laser-powder bed fusion processes often rely on assumptions and simplifications to reduce their computational expense. One common simplification is in the description of latent heat evolution during the solid-liquid phase change (i.e., the solidification pathway), justified by the fact that the mushy zone thickness is similar to the numerical grid spacing used for continuum transport models. The lack of resolution of transport phenomena in the mushy zone motivates the use of computationally convenient solidification paths such as linear or sigmoidal relationships over pathways derived from fundamental solidification theory such as equilibrium or Scheil models. In the present work, an uncertainty quantification (UQ) framework is used to analyze the influence of solidification pathway selection on the solidification dynamics and melt pool geometries in laser based additive manufacturing (AM) of IN625. Results show the solidification pathway has a quantifiable influence on the cooling rate at the liquidus isotherm, mushy zone thickness, and solidification time. Due to similarities in the latent heat evolution at the beginning of solidification, the equilibrium and Scheil models predict similar cooling rates near the liquidus isotherm, however the wider freezing range of Scheil leads to a wider mushy zone compared to equilibrium. The non-physical latent heat release profiles of sigmoidal and linear paths lead to significant overpredictions of cooling rates at the liquidus isotherm compared to equilibrium and Scheil. Finally, these results indicate that careful consideration should be given to the choice of solidification pathway to ensure reliable model predictions.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Growth of CuFeO 2 single crystals by the optical floating-zone technique

CuFeO 2 single crystals up to 50 mm in length and up to 10 mm in diameter were grown by the optical floating-zone method. Stoichiometric polycrystalline rods with a diameter of 6–12 mm were used as feed materials to produce crystals of sufficient size to be used as substrates for the growth of thin films of delafossites. For stable growth along the c-axis, low growth rates of 0.4 mm/h are necessary. Due to the incongruent melting behavior of CuFeO 2 , a stable melt zone requires adjustment of the lamp power during growth. The melting of CuFeO 2 is not simply incongruent because the thermodynamic equilibrium includes more than two solid phases and the melt; the gas phase is also involved. Finaly, the crystals were characterized by X-ray diffraction and X-ray fluorescence measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Processing behavior evolution of recycled polypropylene: An integrated experimental and Computer-Aided engineering simulation study

Polypropylene (PP) comprises 21% of global plastics production and 18% of plastics waste, yet less than 1% of solid-waste PP is recycled in the United States (U.S.), representing significant environmental and economic challenges. Mechanical recycling, the most prevalent recycling method, subject's materials to thermomechanical stresses, which typically degrade polymer properties, affecting the quality of polymer products. This study replicates the impact of mechanical recycling through multiple extrusion cycles to examine the effects on PP's processing behavior. Dynamic scanning calorimetry (DSC) measurements showed stable melting behavior across all processing conditions, while crystallization analysis exhibited consistent shifts in kinetic parameters. Rheological characterization demonstrated progressive viscosity reductions through successive cycles, particularly pronounced at elevated reprocessing temperatures. Here, the integration of this experimental data into injection molding simulations showed that recycled PP maintains viable processing characteristics. Our findings establish quantitative correlations between processing history and material behavior, enabling optimization of processing parameters directly rather than relying on trial-and-error approaches. While these results reflect idealized recycling conditions with minimal contamination, they provide a framework for understanding fundamental property evolution during mechanical recycling.

42 ENGINEERING↗
DOE OSTI2026

Tunable PA6 Polymer System for Thermoplastic Reinforced Body Panels

Project Goal: Overall, a redesigned polyamide system will combine the ductility and processing of a PA6 matrix, the strength and modulus of CF, and the facile recyclability of esters. Approach: PEA can be synthesized under conventional, industrially relevant pathways. Material properties and processing will be analyzed and compared to commercial PA6 material. Results: Polycondensation, traditional for polyesters, was successful in synthesized a PEA. PEA exhibited fast crystallization and bimodal melting behavior suggesting beneficial crystallization kinetics. PEA exhibit reduced melting temperatures owed to the incorporation of ester units in the polymer structure.

42 ENGINEERING↗
DOE OSTI2022

Stabilization of the Polar Structure and Giant Second-Order Nonlinear Response of Single Crystal γ-NaAs 0.95 Sb 0.05 Se 2

The dearth of suitable materials significantly restricts the practical development of infrared (IR) laser systems with highly efficient and broadband tuning. Recently, γ-NaAsSe 2 is reported, and it exhibits a large nonlinear second-harmonic generation (SHG) coefficient of 590 pm V —1 at 2 µm. However, the crystal growth of γ-NaAsSe 2 is challenging because it undergoes a phase transition to centrosymmetric δ-NaAsSe 2 . Herein, the stabilization of non-centrosymmetric γ-NaAsSe 2 by doping the As site with Sb, which results in γ-NaAs 0.95 Sb 0.05 Se 2 is reported. The congruent melting behavior is confirmed by differential thermal analysis with a melting temperature of 450 °C and crystallization temperature of 415 °C. Single crystals with dimensions of 3 mm × 2 mm are successfully obtained via zone refining and the Bridgman method. The purification of the material plays a significant role in crystal growth and results in a bandgap of 1.78 eV and thermal conductivity of 0.79 Wm —1 K —1 . The single-crystal SHG coefficient of γ-NaAs 0.95 Sb 0.05 Se 2 exhibits an enormous value of |d 11 | = 648 ± 74 pm V —1 , which is comparable to that of γ-NaAsSe 2 and ≈20× larger than that of AgGaSe 2 . Importantly, the bandgap of γ-NaAs 0.95 Sb 0.05 Se 2 (1.78 eV) is similar to that of AgGaSe 2 , thus rendering it highly attractive as a high-performing nonlinear optical material.

36 MATERIALS SCIENCE↗