NASA Office of Biological and
Physical Research &
The University of Alabama in
Huntsville, CMR
A description of a new technique to directly observe the solidification (freezing)
process in metal alloys in real-time by using x-rays. You
will find: images and explainations of what Dr.
William Kaukler and Dr. Peter Curreri can see, how it's done, and what they plan.
Their method of X-ray Microscopy uses a special microfocus x-ray source
to create images of the solid-liquid interface during solidification under
controlled conditions. Features having dimensions below ten micrometers are
being observed and studied in real-time. The information from this fundamental
research is used to produce stronger alloys and composite materials. In
addition, every experiment is an exploration into previously unseen worlds.
Aluminum-Indium Alloy
Radiomicrograph

The first example,
shows the kind of interesting internal structures we can observe. This is a low
magnification post-solidification x-ray micrograph of an aluminum-indium
monotectic alloy unidirectionally solidified (from right to left) while the
level of gravity was cycled up and down (along the long axis of the specimen)
from 1.8 to 0.01 times earth gravity.
This was done by flying the
furnace in a NASA aircraft flown in a special, parabolic trajectory to simulate
the low gravity conditions in space for 20 seconds at a time. Much more can be
found about these aircraft
at NASA Lewis Research Center.
The distribution of the
indium particles that formed during the solidification are periodically
clustered in response to the level of gravity imposed. (The specimen is 5 mm in
diameter.) Such solidification studies are an example of the kind of research
that NASA's Microgravity Science
and Applications Division is responsible for. The X-ray Microscope is
presently too large to use in a microgravity environment but the XTM is used to
examine flight samples before and after the experiments are run on the Shuttle.
They are presently designing a compact version that could be tested on the KC-135.
Some examples of x-ray microscopy during solidification of aluminum alloys (in
the laboratory) using the X-ray Transmission Microscope (XTM).
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Interface of Aluminum-Lead (Al-Pb) alloy showing
liquid (dark left side) and solid. Solidification is progressing from
right to left. The solid portion on the right shows three regions with
different growth rates as marked. The band structure in the solid (zebra
stripes vertical) changes spacing with this growth rate change. The liquid
near the solid is quite dark due to the accumulation of the dense lead
(Pb) in the liquid. This is a solute layer formed by the rejection of the
lead by the solid and can only diffuse away into the liquid away from the
interface. This rejection is a normal solidification phenomenon but has
never been photographed before in a metal alloy.
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Interface of Aluminum-2% Silver (Al-Ag) alloy showing
liquid (melt) on the left side and solid Al 'fingers' on the right.
Solidification is progressing from right to left. This interface has what
is called a cellular morphology. Constitutional undercooling
(solidification phenomenon in alloys) brought on by the solute (Ag)
buildup during solidification lead to the formation of these fingers of Al
surrounded by Ag-rich melt. These cells are about 75 µm across. Since the
cells are so small, they overlap in layers and it is not easy to delineate
them except when you are lucky find a clean area like here. The growth
rate is 2 µm/sec. The image was taken with a 2 second exposure with 55 kV
acceleration and 200 µA input current.
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Interface of Aluminum-Indium (Al-In) alloy showing
how the Indium solute is collecting ahead of the solid in the liquid
region during growth as solidification progresses from right to left. The
dark cloud to the left of the interface is this solute layer in the liquid
(melt). The darker portion on the right was solidified at a slower rate
than the light colored part between the interface and this darker region.
It is this higher growth rate that is causing the more solute to be
collected ahead of the interface in the liquid instead of being deposited
in the solid thus making the solid 'lighter' or less absorbing to x-rays.
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Interface of Aluminum-2% Silver (Al-Ag) alloy about
to engulf a gas bubble that formed in the melt. The interface itself is
growing with a cellular structure due to the build-up of silver in the
melt resulting in constitutional supercooling that leads to the interface
breakdown. (See also image above.) The extra silver in the liquid accounts
for the darker appearance of the melt and in the cell walls. This is the
first image of its kind showing the growing cellular interface AND the
engulfment of the void. The growth rate is 2 µm/sec and the thermal
gradient is 47 degrees C per centimeter.
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This work is being performed by Dr.
William Kaukler and Dr. Peter Curreri at Marshall
Space Flight Center in Huntsville, Alabama.
Source: Nasa
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