Gravity has profound influences on most solidification and crystal growth processes. Modification of gravity over practical time scales for the purposes of modifying or controlling solidification proves to be a far more daunting and expensive technological challenge. This article discusses various microgravity solidification experiments that involve pure metals, alloys, and semiconductors and presents the official NASA acronyms for them. MEPHISTO, TEMPUS, the isothermal dendritic growth experiment, and advanced gradient heating facility, are also discussed.

For a wide range of new or better products, solidification processing of metallic materials from the melt is a step of uppermost importance in the industrial production chain. This article discusses the casting and solidification of molten metallic alloy along with the application of low-gravity platforms and facilities for solidification processing. It provides a description of dendritic growth studies and electromagnetic levitation. The article concludes with information on the in situ and real-time monitoring of solidification processing.

Welding as an assembly process has become increasingly more attractive to designers of space structures because of its sufficient strength, endurance, reliability during their service lives, and ease of repair. This article reviews a variety of applications for welding in space and low-gravity environments and describes the unique aspects of the space environment. It compares the applicable welding processes, namely, electron-beam welding, laser-beam welding, and gas-tungsten arc welding and examines the metallurgy of low-gravity welds. Steps taken to ensure the continued development of welding technology in space are also discussed.

The measurement of thermophysical properties of metal alloys, especially at high temperatures, is difficult because of the reactivity of some alloys. This article reviews the methods available for measurement of thermal and other physical properties for liquid, semi-solid, and solid commercial alloys, including adiabatic calorimetry, modulated calorimetry, Calvet calorimetry, single-pan calorimetry, and drop calorimetry. It describes differential scanning calorimetry and differential temperature analysis for measuring transition temperatures such as phase transformation or glass transition temperatures. The article schematically illustrates the laser flash apparatus for measuring the thermal diffusivity of solids and oscillation viscometer for measurements of the viscosity of metals. A summary of the measurement methods is presented in tables.

The objective of quantitative metallography/stereology is to describe the geometric characteristics of the features. This article discusses the geometric attributes of microstructural features that can be divided into: the numerical extents and the number density of microstructural features; derived microstructural properties; feature specific size, shape, and orientation distributions; and descriptors of microstructural spatial clustering and correlations. It emphasizes on the practical aspects of the measurement techniques and applications. The article also provides information on the quantitative metallographic methods for estimation of volume fraction, total surface area per unit volume, and total length of per unit volume.

This article discusses the solidification of a matrix alloy in cast metal matrix composites (MMCs). It begins with a discussion on the mixing techniques in reinforcement incorporation and wettability of reinforcement. It describes the solidification processes, such as stir mixing and melt infiltration, used in the synthesis of MMCs. The article also considers the fundamentals of the process and presents a computational modeling of particle/solidification front interactions in metal-ceramic systems. The article concludes with information on nanocomposites.

This article discusses process simulation applications such as casting, powder metallurgy, machining, surface engineering, heat treatment, and joining. The implementation of modeling and simulation tools requires accurate descriptions of material properties and process boundary conditions. The article describes the role of input data and boundary conditions for process simulations. It provides information on the critical enablers of computational materials engineering, such as the computational speed, computational materials engineering software/hardware supply chain, and cost structure for virtual versus physical manufacturing and analysis.

Three-dimensional microscopy can be used to reveal the shape, distribution, and connectivity of three-dimensional (3D) features that lie buried within an opaque material. This article discusses several experimental techniques that can be used to generate 3D images. These include serial sectioning, focused ion beam tomography, atom probe tomography, and X-ray microtomography. Nine case studies are presented that represent the work of the various research groups currently working on 3D microscopy using serial sectioning and illustrate the variants of the basic experimental techniques. The article also discusses the techniques for reconstruction and visualization of 3D microstructures with advanced computer software and hardware.

This article discusses continuum modeling, which is the most relevant approach in modeling grain growth, densification, and deformation during sintering. Continuum plasticity models are frequently used to describe the mechanical response of metal powders during compaction. The article illustrates the typical procedure for computer simulation for press and sinter process. It describes the procedure to obtain the material properties based on the generalized Shima-Oyane model. The article presents a wide variety of tests, accounting for data on the grain growth, densification, and distortion where these data help in the development of a constitutive model for sintering simulation. Finally, the article provides information on the simulation approaches used to optimize die compaction and sintering.

This article presents the governing equations and methodologies to model the press and sinter powder metallurgy, including continuum, micromechanical, multiparticle, and molecular dynamics approaches. It describes the constitutive relation for compaction and sintering. The article discusses the experimental determination of material properties and simulation verification for compaction and sintering. It reviews the use of modeling and simulation of press and sinter powder metallurgy, including gravitational distorting in sintering, compaction optimization, sintering optimization, and coupled press and sinter optimization.

There are several main sources of thermophysical property data that provide the most authoritative and comprehensive compilations of critically and systematically evaluated data that are presently available. This article provides thermophysical property data to assist in the materials properties selection for the simulation of casting processes. The measurements of thermophysical property are difficult due to high temperatures and the reactivity of some alloys. The article discusses the strategies adopted to minimize the effects of high temperatures and reactivity of alloys. It presents the thermophysical properties of pure metals and some commercial alloys and tabulates the enthalpy of fusion and solidus and liquidus temperatures for various alloys of commercial interest. The article also lists the density, thermal conductivity, surface tension, and viscosity for some commercial alloys.

This article presents typical values for the most used types of thermophysical property data that are needed for processing and modeling of solidification and casting processes. It describes methods to determine thermophysical properties, such as specific heat capacity and enthalpy of transformation; enthalpy of melting; solidus and liquidus temperatures; coefficient of thermal expansion; density; surface tension; viscosity; electrical and thermal conductivity; and emissivity.