Rapid solidification of metallic particulates

In order to maximize the heat transfer coefficient the most important variable in rapid solidification is the powder particle size. The finer the particle size, the higher the solidification rate. Efforts to decrease the particle size diameter offer the greatest payoff in attained quench rate. The velocity of the liquid droplet in the atmosphere is the second most important variable. Unfortunately the choices of gas atmospheres are sharply limited both because of conductivity and cost. Nitrogen and argon stand out as the preferred gases, nitrogen where reactions are unimportant and argon where reaction with nitrogen may be important. In gas atomization, helium offers up to an order of magnitude increase in solidification rate over argon and nitrogen. By contrast, atomization in vacuum drops the quench rate several orders of magnitude

The role of rapid solidification processing in the fabrication of fiber reinforced metal matrix composites

Advanced composite processing techniques for fiber reinforced metal matrix composites require the flexibility to meet several widespread objectives. The development of uniquely desired matrix microstructures and uniformly arrayed fiber spacing with sufficient bonding between fiber and matrix to transmit load between them without degradation to the fiber or matrix are the minimum requirements necessary of any fabrication process. For most applications these criteria can be met by fabricating composite monotapes which are then consolidated into composite panels or more complicated components such as fiber reinforced turbine blades. Regardless of the end component, composite monotapes are the building blocks from which near net shape composite structures can be formed. The most common methods for forming composite monotapes are the powder cloth, foil/fiber, plasma spray, and arc spray processes. These practices, however, employ rapid solidification techniques in processing of the composite matrix phase. Consequently, rapid solidification processes play a vital and yet generally overlooked role in composite fabrication. The future potential of rapid solidification processing is discussed

Solute trapping and diffusionless solidification in a binary system

Numerous experimental data on the rapid solidification of binary systems exhibit the formation of metastable solid phases with the initial (nominal) chemical composition. This fact is explained by complete solute trapping leading to diffusionless (chemically partitionless) solidification at a finite growth velocity of crystals. Special attention is paid to developing a model of rapid solidification which describes a transition from chemically partitioned to diffusionless growth of crystals. Analytical treatments lead to the condition for complete solute trapping which directly follows from the analysis of the solute diffusion around the solid-liquid interface and atomic attachment and detachment at the interface. The resulting equations for the flux balance at the interface take into account two kinetic parameters: diffusion speed $V_{DI}$ on the interface and diffusion speed $V_D$ in bulk phases. The model describes experimental data on nonequilibrium solute partitioning in solidification of Si-As alloys [M.J. Aziz et al., J. Cryst. Growth {\bf 148}, 172 (1995); Acta Mater. {\bf 48}, 4797 (2000)] for the whole range of solidification velocity investigated.Comment: Regular article in Physical Review E, Vol. 76 (2007

Thrust chamber material technology program

This report covers work performed at Pratt & Whitney on development of copper-based materials for long-life, reusable, regeneratively cooled rocket engine thrust chambers. The program approached the goal of enhanced cyclic life through the application of rapid solidification to alloy development, to introduce fine dispersions to strengthen and stabilize the alloys at elevated temperatures. After screening of alloy systems, copper-based alloys containing Cr, Co, Hf, Ag, Ti, and Zr were processed by rapid-solidification atomization in bulk quantities. Those bulk alloys showing the most promise were characterized by tensile testing, thermal conductivity testing, and elevated-temperature, low-cycle fatigue (LFC) testing. Characterization indicated that Cu- 1.1 percent Hf exhibited the greatest potential as an improved-life thrust chamber material, exhibiting LCF life about four times that of NASA-Z. Other alloys (Cu- 0.6 percent Zr, and Cu- 0.6 percent Zr- 1.0 percent Cr) exhibited promise for use in this application, but needed more development work to balance properties

INEL Spray-forming Research

Spray forming is a near-net-shape fabrication technology in which a spray of finely atomized liquid droplets is deposited onto a suitably shaped substrate or mold to produce a coherent solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g., refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials. Results from several spray forming programs are presented to illustrate the range of capabilities of the technique as well as the accompanying technical and economic benefits. Low-carbon steel strip greater than 0.75 mm thick and polymer membranes for gas/gas and liquid/liquid separations that were spray formed are discussed; recent advances in spray forming molds, dies, and other tooling using low-melting-point metals are described

Faster - Better Molds Through RSP Tooling New Research and Advancements

The recent developments in rapid production tooling have all but made the need for prototype tooling disappear. There are several approaches that are now as fast and inexpensive as prototype tooling, and after part approval can continue to run in high volume production applications. The newest of these approaches is an indirect spray forming process invented by Dr. Kevin McHugh of the Idaho National Engineering and Environmental Laboratories (INEEL). The advantages of RSP Tooling can be found in its accuracy, finish, cost and speed compared to the other rapid tooling processes [1]. The commercialization effort for this spray forming process started in February of 2002. The beta production machine was operational in November, 2003, and started to produce production tooling in March, 2004. Since that time tooling has been manufactured and run for many forming applications. In all but the simplest tools the process has proven to be less expensive and faster than standard machining of tools or any other rapid production tooling process. Research and development of the process has continued both at INEEL and at RSP Tooling, LLC making the process faster, more accurate and less expensive to operate. This research has also generated a better understanding of the underlying metallurgy of the process.Mechanical Engineerin

Effect of alloying elements in melt spun Mg-alloys for hydrogen storage

In this paper we report the effect of alloying elements on hydrogen storage properties of melt-spun Mg-based alloys. The base alloys Mg90Si10, Mg90Cu10, Mg65Cu35 (at%) were studied. We also investigated the effect of rare earths (using MM: mischmetal) and Al in Mg65Cu25Al10, Mg65Cu25MM10 and Mg65Cu10Al15MM10 alloys. All the melt-spun alloys without MM show a crystalline structure, and the Mg65Cu25MM10 and Mg65Cu10Al15MM10 alloys showed an amorphous and partially amorphous structure respectively. At 350˚C all the alloys had a crystalline structure during the hydrogen absorption-desorption tests. It was observed that Si and Cu in the binaries alloys hindered completely the activation of thehydrogen absorption. The partial substitution of Cu by MM or Al allowed activation. The combined substitution of Cu by MM and Al showed the best results with the fastest absorption and desorption kinetics, which suggests that this combination can be used for new Mg-alloys to improve hydrogen storage properties.Fil: Rozenberg, Silvia. Consejo Nacional de Investigaciones Científicas y Técnicas. Oficina de Coordinación Administrativa Houssay. Instituto de Tecnologías y Ciencias de la Ingeniería ; ArgentinaFil: Saporiti, María Fabiana Sonia. Consejo Nacional de Investigaciones Científicas y Técnicas. Oficina de Coordinación Administrativa Houssay. Instituto de Tecnologías y Ciencias de la Ingeniería ; ArgentinaFil: Lang, Julien. Université du Québec a Montreal; CanadáFil: Audebert, Fernando Enrique. Consejo Nacional de Investigaciones Científicas y Técnicas. Oficina de Coordinación Administrativa Houssay. Instituto de Tecnologías y Ciencias de la Ingeniería "Hilario Fernández Long". Universidad de Buenos Aires. Facultad de Ingeniería. Instituto de Tecnologías y Ciencias de la Ingeniería "Hilario Fernández Long"; ArgentinaFil: Botta, Pablo Martín. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Mar del Plata. Instituto de Investigaciones en Ciencia y Tecnología de Materiales. Universidad Nacional de Mar del Plata. Facultad de Ingeniería. Instituto de Investigaciones en Ciencia y Tecnología de Materiales; ArgentinaFil: Stoica, Mihai. Leibniz Institute for Solid State and Materials Research Dresden; AlemaniaFil: Huot, Jacques. Université du Québec a Montreal; CanadáFil: Eckert, Jürgen. The Erich Schmid Institute of Materials Science; Austri