Compact x-ray microradiograph for in situ imaging of solidification processes: bringing in situ x-ray micro-imaging from the synchrotron to the laboratory

In-situ X-ray monitoring of solidification and related processes of metal alloys

X-ray radioscopy enables the in-situ monitoring of metal alloy processes and then gives access to crucial information on the dynamics of the underlying phenomena. In the last decade, the utilisation of this powerful imaging technique has been adapted to microgravity platforms such as sounding rockets and parabolic flights. The combination of microgravity experimentation with X-ray radioscopy has resulted in a leap in the understanding of fundamental science and has opened new paths in the fields of materials science. The present review focuses on the short history of this research, which includes facility developments, microgravity experiments and results obtained by partners of the XRMON (In-situ X-Ray MONitoring of advanced metallurgical processes under microgravity and terrestrial conditions) research project in the framework of the MAP (Microgravity Application Promotion) programme of the European Space Agency. Three illustrative research topics that were advanced significantly through the use of X-ray radioscopy will be detailed: solidification of metal alloys, metallic foam formation and diffusion in melts.

Investigating Metal Solidification with X-ray Imaging

In the last two decades, X-ray imaging techniques have been used increasingly to study metal solidification in real-time as, thanks to advances in X-ray sources (synchrotron and laboratory-based) and detector technology, images can now be obtained with spatio-temporal resolutions sufficient to record key phenomena and extract quantitative information, primarily relating to crystal growth. This paper presents an overview of the research conducted at the University of Oxford over the last 6 years as a partner in the UK’s Future Liquid Metal Engineering (LiME) Manufacturing Hub. The focus is on in situ X-ray radiography to investigate the solidification of Al alloys, including the formation of primary α-Al crystals, and the formation and growth of secondary intermetallic phases. Technologically, the thrust is to understand how to control as-cast phases, structures and element distributions, particularly elements associated with recycling, as a means to facilitate greater recirculation of aluminium alloys. We first present studies on refinement of primary α-Al, including extrinsic grain refinement using inoculation and intrinsic refinement based on dendrite fragmentation. Second, we describe studies on intermetallic phase formation and growth, because intermetallic fraction, morphology and distribution are frequently a limiting factor of alloy mechanical properties and recyclability. Then we present some of the latest progress in studying liquid flow during solidification and associated hot tear formation. Finally, future research directions are described.

X-ray Imaging of Alloy Solidification: Crystal Formation, Growth, Instability and Defects

Synchrotron and laboratory-based X-ray imaging techniques have been increasingly used for in situ investigations of alloy solidification and other metal processes. Several reviews have been published in recent years that have focused on the development of in situ X-ray imaging techniques for metal solidification studies. Instead, this work provides a comprehensive review of knowledge provided by in situ X-ray imaging for improved understanding of solidification theories and emerging metal processing technologies. We first review insights related to crystal nucleation and growth mechanisms gained by in situ X-ray imaging, including solute suppressed nucleation theory of α-Al and intermetallic compound crystals, dendritic growth of α-Al and the twin plane re-entrant growth mechanism of faceted Fe-rich intermetallics. Second, we discuss the contribution of in situ X-ray studies in understanding microstructural instability, including dendrite fragmentation induced by solute-driven, dendrite root re-melting, instability of a planar solid/liquid interface, the cellular-to-dendritic transition and the columnar-to-equiaxed transition. Third, we review investigations of defect formation mechanisms during near-equilibrium solidification, including porosity and hot tear formation, and the associated liquid metal flow. Then, we discuss how X-ray imaging is being applied to the understanding and development of emerging metal processes that operate further from equilibrium, such as additive manufacturing. Finally, the outlook for future research opportunities and challenges is presented.

Recent Development in X-Ray Imaging Technology: Future and Challenges

X-ray imaging is a low-cost, powerful technology that has been extensively used in medical diagnosis and industrial nondestructive inspection. The ability of X-rays to penetrate through the body presents great advances for noninvasive imaging of its internal structure. In particular, the technological importance of X-ray imaging has led to the rapid development of high-performance X-ray detectors and the associated imaging applications. Here, we present an overview of the recent development of X-ray imaging-related technologies since the discovery of X-rays in the 1890s and discuss the fundamental mechanism of diverse X-ray imaging instruments, as well as their advantages and disadvantages on X-ray imaging performance. We also highlight various applications of advanced X-ray imaging in a diversity of fields. We further discuss future research directions and challenges in developing advanced next-generation materials that are crucial to the fabrication of flexible, low-dose, high-resolution X-ray imaging detectors.

Analysis of gravity effects during binary alloy directional solidification by comparison of microgravity and Earth experiments with in situ observation

Under terrestrial conditions, solidification processes are influenced to a large degree by the gravity effects such as natural convection or buoyancy force, which can dramatically modify the final characteristics of the grown solid. In the last decades, the coupling of in situ observation of growth from the melt, that enables the study of microstructure formation dynamics, and microgravity experimentation, that allows to approach diffusive conditions, has been implemented for both transparent and metallic materials. The results of these investigations enable to test the validity of advanced solidification theories, to validate or develop numerical models and sometimes to reveal unexpected phenomena. The aim of this paper is to present a selection of conclusive experiments obtained with this combined approach in our group to highlight the gravity effects by a comparative study of experiments carried out on earth and in microgravity conditions.

Isothermal furnace for long-term in situ and real-time X-radiography solidification experiments

A new x-ray isothermal furnace has been developed, suitable for in situ observations of semi-solid processes including the transition from dendritic to globulitic grain morphology and grain coarsening in metallic samples. A homogeneous, isothermal temperature field is achieved using a novel heater concept. The furnace structure is sandwich-like with heating elements positioned in the beam line and parallel to the sample. Planar heat transfer to the sample enables measurements with low cooling rates and a minimized temperature gradient. Cooling rates from 0.1 to 15 K min^-1 can be controlled in the temperature range 1170-670 K. The furnace setup is integrable in the existing rotatable laboratory x-ray facility (X-RISE) at the German Aerospace Center (DLR). In this setup, an effective pixel size of 3 μm and a field of view of 8 mm in diameter can be achieved. Preliminary solidification and semi-solid experiments in the hypo-eutectic alloy systems Al-Ge and Al-Cu, inoculated with Al-5Ti-1B grain refiner, are presented. They indicate a very uniform temperature distribution in the sample.

In Silico Phase-Contrast X-Ray Imaging of Anthropomorphic Voxel-Based Phantoms

Propagation-based phase-contrast X-ray imaging is an emerging technique that can improve dose efficiency in clinical imaging. In silico tools are key to understanding the fundamental imaging mechanisms and develop new applications. Here, due to the coherent nature of the phase-contrast effects, tools based on wave propagation (WP) are preferred over Monte Carlo (MC) based methods. WP simulations require very high wave-front sampling which typically limits simulations to small idealized objects. Virtual anthropomorphic voxel-based phantoms are typically provided with a resolution lower than imposed sampling requirements and, thus, cannot be directly translated for use in WP simulations. In the present paper we propose a general strategy to enable the use of these phantoms for WP simulations. The strategy is based on upsampling in the 3D domain followed by projection resulting in high-resolution maps of the projected thickness for each phantom material. These maps can then be efficiently used for simulations of Fresnel diffraction to generate in silico phase-contrast X-ray images. We demonstrate the strategy on an anthropomorphic breast phantom to simulate propagation-based phase-contrast mammography using a laboratory micro-focus X-ray source.

Near-isothermal furnace for in situ and real time X-ray radiography solidification experiments

In this paper, we present a newly developed near-isothermal X-ray transparent furnace for in situ imaging of solidification processes in thin metallic samples. We show that the furnace is ideally suited to study equiaxed microstructure evolution and grain interaction. To observe the growth dynamics of equiaxed dendritic structures, a minimal temperature gradient across the sample is required. A uniform thermal profile inside a circular sample is achieved by positioning the sample in the center of a cylindrical furnace body surrounded by a circular heater arrangement. Performance tests with the hypo-eutectic Al-15wt.%Cu and the near-eutectic Al-33wt.%Cu alloys validate the near-isothermal character of the sample environment. Controlled cooling rates of less than 0.5 K min(-1) up to 10 K min(-1) can be achieved in a temperature range of 720 K-1220 K. Integrated in our rotatable laboratory X-ray facility, X-RISE, the furnace provides a large field of view of 10.5 mm in diameter and a high spatial resolution of ∼4 μm. With the here presented furnace, equiaxed dendrite growth models can be rigorously tested against experiments on metal alloys by, e.g., enabling dendrite growth velocities to be determined as a function of undercooling or solutal fields in front of the growing dendrite to be measured.