Search NASA⌕ Search

SEARCH · Search NASA

Results for “spattering”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

A Novel Additive Manufacturing Process Metric for Predicting Spatter-related Porosity in Laser Powder Bed Fusion

Components fabricated using the powder bed fusion laser beam metallic (PBF) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Porosity defects resulting from weld pass inconsistencies are a concern for PBF materials and have a strong adverse effect on the mechanical properties. In an effort to understand and avoid spatter induced porosity, this work aims to provide a novel computational technique that can be used to quantify and predict the sequence-sensitive impact of spatter upon the PBF process stability and consequential porosity in as-printed material. A novel spatter impact AM model-based process metric (AM-PM) is introduced to model and quantify the impact that spatter has on the PBF process. The occurrence of spatter induced porosity is studied using thermal rise, lack of fusion, and spatter impact AM-PMs synchronized with porosity measured by high-resolution X-ray computed tomography. Six cylindrical specimens were designed to compare the AM-PM correlations with porosity across two different laser powers and three hatch scanning strategies. A point field based computational approach is shown to be effective for testing the influence of the different AM-PMs and interrogating the physical process conditions underlying the porosity formation. Further, characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated with the spatter impact AM-PM, which can be exploited to predict and control spatter related porosity by the hatch strategy. Efforts to predict porosity composition within PBF material should incorporate the PBF process disturbances that can result from spatter. The spatter impact AM-PM can be readily incorporated into the development of defect prediction models at the part scale.

Additive Manufacturing↗
NASA NTRS2024

Correlations of Additive Manufacturing Model-Based Process Metrics With Spatter-Induced Porosity in the Powder Bed Fusion-Laser Beam/Metallic Process

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Qualifying materials for components in critical applications requires a thorough understanding of pertinent processing-microstructure-property relationships. Porosity defects have a strong adverse effect on the mechanical properties of a material. The morphology of porosity defects created by lack of fusion in PBF-LB/M often exhibit high aspect ratios that can act as stress concentrators and become crack initiation sites. The occurrence of spatter induced porosity is studied using synchronized AM model-based process metrics and porosity measured by high-resolution X-ray computed tomography. A novel AM process metric is introduced to quantify the relative exposure to spatter ejecta impacts and incorporation throughout the sequence of the PBF-LB/M process. Further characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated statistically with the spatter ejecta impact field of the PBF-LB/M process. Both keyhole and lack of fusion porosity can be predicted by the spatter exposure process metric, which can be exploited to control the fusion sequence.

Additive Manufacturing↗
NASA NTRS1983

Reduction, partial evaporation, and spattering - Possible chemical and physical processes in fluid drop chondrule formation

The major chemical differences between fluid drop chondrules and their probable parent materials may have resulted from the loss of volatiles such as S, H2O, Fe, and volatile siderophile elements by partial evaporation during the chondrule-forming process. Vertical access solar furnace experiments in vacuum and hydrogen have demonstrated such chemical fractionation trends using standard rock samples. The formation of immiscible iron droplets and spherules by in situ reduction of iron from silicate melt and the subsequent evaporation of the iron have been observed directly. During the time that the main sample bead is molten, many small spatter spherules are thrown off the main bead, thereby producing many additional chondrule-like melt spherules that cool rapidly and generate a population of spherules with size frequency distribution characteristics that closely approximate some populations of fluid drop chondrules in chondrites. It is possible that spatter-produced fluid drop chondrules dominate the meteoritic fluid drop chondrule populations. Such meteoritic chondrule populations should be chemically related by various relative amounts of iron and other volatile loss by vapor fractionation.

King, E. A.↗
NASA NTRSDate not supplied

Correlations Between Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M)additive manufacturing process are the result of a multitude of weld passes conducted sequentially. Qualifying components for aerospace applications requires a thorough understanding of the process-structure-properties relationships. Porosity defects are known to have a strong adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. The results show that lack of fusion porosity is statistically correlated with unremoved welding spatter ejecta of the PBF-LB/M process and process metrics related to the hatching strategy.

Qualification↗
NASA NTRS1986

Linear volcanic features at Alba Patera, Mars - Probable spatter ridges

A number of extensive linear constructional features occur on the north and east flanks of Alba Patera. They are found in a 150-km-wide zone and comprise aligned ridge elements that are locally associated with short volcanic flows. They are among the youngest volcanic features in the region and are believed to be Martian analogs of terrestrial spatter ridges. On the basis of measurements made on Viking images, it appears that active volcanic fissures on Mars were larger than their terrestrial counterparts.

Cattermole, Peter↗
NASA NTRS1982

Refractory residues, condensates and chondrules from solar furnace experiments

Vertical access solar furnace experiments have produced refractory residues, condensates and chondrules that are similar to components of chondritic meteorites. In particular, Ca-Al-rich refractory residues similar in chemistry to inclusions in carbonaceous chondrites have been produced by partial evaporation of basaltic bulk rock samples. Fe-Mg-Si-rich condensates with distinctive microbotryoidal morphology have been collected from the same sample runs. Particle coatings and aggregates with virtually identical microbotryoidal morphology and major element chemistry have been identified in both the Allende and Murchison meteorites. Spattered drops from melt beads undergoing heating and partial evaporation resemble some meteoritic chondrules in their mineralogies, textures, grain size, and sorting. The spatter mechanism is highly efficient in the production of chondrules. If any of the refractory inclusions in chondrites are, in fact, partial evaporation residues, many meteoritic fluid drop chondrules must have been formed by this process. The hot central portion of the solar nebula, acting on a cloud of dust and gas, is the probable source of heat required to produce the fractionated chemistry and physical state of many of the components of chondritic meteorites.

King, E. A.↗
NASA NTRS1964

Some characteristics of black spherules.

Black spherules from Greenland ice sheets compared to industrial weld-spatter spherules, using density measurements coupled with chemical analysis

EXTRATERRESTRIAL MATTER↗
NASA NTRS1972

Submerged arc welding of heavy plate

The submerged arc process is particularly suitable for heavy plate welding because of its ability to combine very high deposit rates along with excellent quality. It does these things without the smoke and spatter often accompanying other processes. It is available today in several forms that are pointed to the fabricators of heavy sections with long, short or round about welds. Tandem arc full automatic equipment is particularly suitable for those long heavy welds where speed and deposit rate are of the first order. An attachment called long stick-out which makes use of the IR drop on long electrode extensions can be included on this equipment to increase deposition rates 50% or more.

Wilson, R. A.↗
NASA NTRS1975

Stratification in the lunar regolith - A preliminary view

Although our knowledge of lunar regolith stratification is incomplete, several categories of thick and thin strata have been identified. Relatively thick units average 2 to 3 cm in thickness, and appear surficially to be massive. On more detailed examination, these units can be uniformly fine-grained, can show internal trends, or can show internal variations which apparently are random. Other thick units contain soil clasts apparently reworked from underlying units. Thin laminae average approximately 1 mm in thickness; lenticular distribution and composition of some thin laminae indicates that they are fillets shed from adjacent rock fragments. Other dark fine-grained well-sorted thin laminae appear to be surficial zones reworked by micrometeorites. Interpretations of stratigraphic succession can be strengthened by the occurrence of characteristic coarse rock fragments and the orientation of large spatter agglutinates, which are commonly found in their original depositional orientation.

Duke, M. B.↗
NASA NTRS1978

Scanning Electron Microscopy and Petrography of Glassy Particles Produced by Lava Fountain Eruptions

A conceptual model of a lava fountain consists of a vent, spatter ramparts, fountain column, downwind plume and associated pumice deposits. Glassy particles produced by lava fountain eruptions consist primarily of sideromelane glass and minor to moderate amounts of vesicles and crystals. Particles are classified on the basis of morphology as: (1) spherical, (2) elongate, (3) glass-coated mineral grain, (4) shard, (5) reticulite, (6) composite particle, and (7) lithic fragment.

Ladle, G. H.↗
NASA NTRS1980

Volcanic features of Hawaii. A basis for comparison with Mars

Despite the difference in size Martian and Hawaiian volcanoes have numerous characteristics in common. Specific features such as lava channels, collapsed lava tubes, levees and flow fronts, all very common in Hawaii, are also abundant on the flanks of some of the Martian volcanoes. Striking differences also exist, such as the apparent lack of radial rift zones on some Martian volcanoes and the paucity of cinder and spatter cones. Some of the best photographs of Martian and Hawaiian volcanic features are presented. Descriptive legends are provided for each picture. An overview of the geological processes and structures depicted is included.

Carr, M. H.↗
NASA NTRS1982

Material Protection During Electron-Beam Welding

Alumina pellets behind electron-beam weld joint protect other parts of assembly from beam and from spattered material. Alumina pellets may be cleaned and reused. Easily applied and removed in regions that are narrow or have complex shapes.

Tomlinson, R. L.↗
NASA NTRS1982

Magma vesiculation and pyroclastic volcanism on Venus

Theoretical consideration of the magma vesiculation process under observed and inferred venusian surface conditions suggests that vesicles should form in basaltic melts, especially if CO2 is the primary magmatic volatile. However, the high surface atmospheric pressure (about 90 bars) and density on Venus retard bubble coalescence and disruption sufficiently to make explosive volcanism unlikely. The products of explosive volcanism (fire fountains, convecting eruption clouds, pyroclastic flows, and topography-mantling deposits of ash, spatter, and scoria) should be rare on Venus, and effusive eruptions should dominate. The volume fraction of vesicles in basaltic rocks on Venus are predicted to be less than in chemically similar rocks on earth. Detection of pyroclastic landforms or eruption products on Venus would indicate either abnormally high volatile contents of Venus magmas (2.5-4 wt%) or different environmental conditions (e.g., lower atmospheric pressure) in previous geologic history.

Garvin, J. B.↗
NASA NTRS1987

Preliminary results of geologic and remote sensing studies of Rima Mozart

In order to better understand the processes responsible for the formation of lunar sinuous rilles, a study of Rima Mozart was conducted using a variety of geologic, photographic, and remote sensing data. The apparent source of this rille is located in a highlands unit of known composition and it is hypothesized that thermal and mechanical erosion played an important role in the formation of Rima Mozart. Excellent photographic, topographic, multispectral, and radar data exist for this rille. The preliminary results of an analysis of this data are presented. Photographic data indicates the presence of two volcanic source vents for Rima Mozart: Kathleen and Ann. It is suggested that Rima Mozart, like many other lunar sinuous rilles, was most likely formed by a combination of events. Rima Mozart does follow a pre-existing, dominant NW/SE structural trend suggesting the influence of structural features on the rille, however, the tectonic influence is not the sole source for the formation of the rille, as suggested by the presence of the two source vents and the spatter around Ann. It is suggested that the rille formation began with an explosive eruption at Kathleen which later calmed down to a pulsating, high volume, low-viscosity lava flow. The rapid effusion rate of the magma as well as its high temperature and turbid nature helped carve the sinuous rille into the fractured and structurally weak Apennine Bench Formation underneath. Similar eruptions and subsequent flows were also created at Ann and joined to the main channel by a NE-trending secondary rille.

Coombs, C. R.↗
NASA NTRS1988

Protective Coating For Laser Drilling Of Silicon

Sodium silicate prevents spattered silicon from fusing with surrounding material. Sodium silicate solution applied to wafer by dipping and draining or by spinning; application by spraying also works. When dried in oven, solution leaves thin coating of sodium silicate glass.

Shlichta, Paul J.↗
NASA NTRS1988

Laser Micromachining In A Reactive Atmosphere

Drilling of deep holes in silicon by laser beam aided by conducting operation in reactive atmosphere. Atmosphere reacts with material ejected from hole and converts material to gas flowing away from work area. Hole cleaner and more sharply defined, and debris do not spatter surface of work.

Shlichta, Paul J.↗