X-Ray Microscope for Metal Solidification Studies. A research used to produce stronger alloys and composite materials

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).

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.

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.

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.

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.

This work is being performed by Dr. William Kaukler and Dr. Peter Curreri at Marshall Space Flight Center in Huntsville, Alabama.

Source: Nasa





 
Market Watch
 
  • News
  •  
  • Market Facts
  •        - Statistics
     
  • Products
  •        - Traditional
           - Cutting Edge
     
  • Production Processes
  •  
  • R&D
  •  
  • Recycling
  •  
  • Exhibitions & Conferences
  •  
  • Applications
  •  
  • Publications
  •  
  • History of Aluminium
  •  

    Top 5 News
    Alcoa Completes Traco Acquisition
    Hydro takes full control of Taiwan remelter
    Alcoa to Acquire Traco
    Alufoil sales back on pre-crisis level
    Aleris Europe announces price increase for aluminum coil and sheet products  

    Google

    LME_50.gif (924 bytes)
    London Metal Exchange

    Official Prices
    Primary: Link here to see yesterday's closing prices
    Price Graphs
    Formulate your own price graph of aluminium prices using the LME databank





    Copyright © 1999 aluNET International. All rights reserved
    To our best knowledge the above information is correct. Please read the disclaimer.