A new hypothesis has been developed to explain the effect of internal fluid flow on the lifetime of a metastable phase in solidifying Fe-Cr-Ni alloys. The hypothesis shows excellent agreement with available experimental results, but microgravity experiments are required for complete validation. Certain Fe-Cr-Ni stainless steel alloys solidify from an undercooled melt by a two-step process in which the metastable ferrite phase forms first followed by the stable austenite phase. Recent experiments using containerless processing techniques have shown that the lifetime of the metastable phase is strongly influenced by flow within the molten sample. Simulations using a commercial computational fluid dynamics (CFD) package, FIDAP, were performed to determine the time required for collision of dendrites and compared to experimental delay time. If the convective velocities are strong enough to bend the primary arms, then the secondary arms of adjacent dendrites can touch. The points of collision form low-angle boundaries and result in high-energy sites that can serve as nuclei for the transformation to the stable phase. It has been determined that the convective velocities in electrostatic levitation (ESL) are not strong enough to cause collision. However, in ground-based electromagnetic levitation (EML), the convective velocities are strong enough to cause the dendrites to deflect so that the secondary arms of adjacent dendrites collide. There is quantitative agreement between the numerically determined time to collision and the experimentally observed delay time in EML. The strong internal velocity due to convection within the EML samples is the reason for the observed difference in delay times between ESL and EML. Microgravity testing is essential because the significant change in nucleation behavior occurs between the ranges accessible by ground-based ESL and EML. Testing in microgravity using EML will permit a large range of internal convective velocities including those that are inaccessible in 1 g.
Differences have been observed between the lifetimes of the metastable phases of undercooled samples of Fe-12 wt% Cr-16 wt% Ni alloy which had been subjected to electromagnetic levitation (EML) and electrostatic levitation (ESL). Internal flow is induced within the samples by positioning forces in EML and much weaker Marangoni forces in ESL. The hypothesis being tested is that the flow within EML samples is strong enough to cause the growing metastable dendrites to deflect so that the secondary arms of adjacent dendrites collide, resulting in early nucleation of the stable phase. Simulations using a commercial computational fluid dynamics software package were performed to determine the time required for collision of the secondary arms to occur. There is quantitative agreement between the numerical time to collision and the experimental lifetime of the metastable phase. It has been determined that the induced convective flow in EML samples is strong enough to cause collision and is the most likely cause of the difference between the lifetimes of the metastable phases in ESL and EML samples.
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