Despite being well established phenomena, solidification principles are experiencing tough challenges in their application to explain microscale transport phenomena in additive manufacturing melt pool. The problem becomes even more complicated when applied to multicomponent bulk metallic glass matrix composites (BMGMC) whose behavior is dubious and still not fully understood. The aim of the present study is to highlight pathways to overcome these challenges. A comprehensive nucleation and growth model based on original KGT theory and Rappaz modification is proposed encompassing actual transient thermophysical BMGMC data to predict evolving microstructure during additive manufacturing. The model is aimed at pictorial representation of in-situ ductile phase dendrite evolution from melt pool during solidification using two-dimensional cellular automaton (CA) methods. It is proposed to be coded in MATLAB® using commercial simulation code ABAQUS® at back end for macroscopic heat transfer model. The results will be compared with experimental values for validation.

With recent developments in fusion engineering, interest has sparked in development of fusion devices for deterrent. Enormous amount of energy generated by combining two light nuclei could be contained and manipulated at will to trigger and accelerate micro explosions (from shock wave, x-rays or ion beam focusing) which finally result in full scale blast. Materials required to make such device are critical. They must possess high strength, high hardness, ductility, formability, drawability, and anisotropic properties. High entropy alloys (HEA) are new class of materials which nicely fulfils this requirement. Essentially, they are solid solutions of multi principal elements (usually > 5) eliminating the need of base metal as in conventional alloys. This gives them many unique properties which may be tailored at will (heat treatment, cold rolling, precipitation, irradiation). They also exhibit excellent directional properties with formation of distinct bands along certain preferred crystallographic planes even in hexagonal close packed structures. These anisotropic properties are strong function of rolling, working, or forging (swaging) direction and can be utilized to benefit. This study encompasses making outer shell of a typical fusion device selected on the basis of the weight, which is a function of area of pay load bay of carrier aircraft.

NASA/ESA/CSA joint venture James Webb Space Telescope is about to be launched. It is hypothesized to operate in near-infrared range. It is also hypothesized to unveil early star formation, galaxies, and universe due to its orbit, point in orbit and orbital motion. It has been under manufacturing for over 20 years at a staggering cost of 10 billion US dollars (most expensive scientific experiment in history). Beryllium (Be) is chosen to be element for construction of its main mirrors due to its high stiffness, low density, low linear coefficient of thermal expansion (α) in cryogenics and high thermal conductivity. It is followed by gold (Au) layer deposition on its (Be) surface to enhance its sensitivity towards infrared radiation as later is hypothesized to bear superior properties. However, serious mistakes have been made in selecting this material for this application. Owing to its crystal structure (hexagonal close packed (hcp)), slip planes (basal, prismatic and pyramidal) and mechanisms of their activation, Be necessitates easy fracture at cryogenic temperature. It has anisotropic properties and prone to transverse fracture under tensile loading. Furthermore, its ductile to brittle transition temperature is very low making it entirely unsuitable for such an application. It is one of most expensive metals on planet. This study constitutes revisiting these fundamental properties and mechanisms which were entirely ignored during materials selection thus rendering whole project useless.

Fusion device and its structure may be designed by various means. Two of most popular are; weight basis (described in previous study by author) and energy basis. In present research, later method is explored and described. Energy basis is based on amount of energy released from device upon detonation followed by explosion. Its beneficial in a sense that device size can be kept as independent variable as compared to dependent in former case. Further, it shortens the design procedure. For example, heat transfer pattern in such approach directly helps in quantifying wall thickness which dictates material, fabrication, and manufacturing route. It may also eliminate anisotropy as wall thickness is direct function of amount of heat at which it will rupture and can be much thinner. Device geometry can also be flexibility controlled as it is no longer dependent on pay load bay capacity. This allows more freedom in designing subsystems (compartments, their locations, focusing, switches, and mixers). Such devices can be more compact and simpler. Few such design configurations are proposed.

Bubble (point defect) – a precursor of fuzz or under dense nanostructure formation is crystal lattice defect. Suitable selection of crystal lattice which inhibit Frenkel pair generation and intrinsically promotes self- interstitial solid solution strengthening contributes effectively towards making plasma facing material. For this, interstitial sites, their size, amount / fraction, positions, tendency of occupation and diffusion parameters (e.g. activation energies (Q), activation volumes) are determined. Fcc iron carbon alloys (austenitic stainless steels AISI / SAE 321, fcc structure, Pearson code cF4, space group Fm3̅m) are proposed as suitable candidates. Along with their room temperature fcc structure having 12 interstitial positions (4 octahedral, 6 coordination sites and 8 tetrahedral, 4 coordination sites / unit cell) to allow insertion of self (iron) atoms, they have excellent corrosion resistance, thermal conductivity, and non- magnetic properties. After their melting, casting, and machining to required dimensions and geometry, stabilizing heat treatment is applied to precipitate all carbon as TiC and prevent formation of Cr23C6 (sensitization). This resist heat and surface degradation and yield excellent architecture which not onlyinhibit Frankel pair generation but will also allow bulk assimilation or surface annihilation (loop punching) of this lattice point defect. A superior thermal, fluid, and structural design augment above. A second choice is presented as Co base superalloys owing to same fcc crystal structure and excellent properties (such as strength, dimensional stability, oxidation resistance) at high temperature.

Space shuttle has been a hall mark of American space program since its inception. Despite its temporary shutdown few years ago, with the recent interest in space exploration which includes revitalizing human outpost in microgravity and transportation required to build it, realize other experiments (e.g. in space telescopes, in space manufacturing) and interplanetary voyages, it has regained attention. Its superior design, manufacturing, materials, performance, durability, and efficiency place it among the best, in fact, the only effort by mankind to build a reusable craft horizontally, launch vertically like a rocket and fly back like a plane. Various requirements emerge during its design (thermal, fluid, acoustics, vibration and structural) and design of its main engine (Aerojet Rocketdyne RS 25) which requires considerable attention, heat transfer being most important. This facilitated and necessitated use of various types of heat exchangers such as single coil, heat pipe, built in internal heat exchanger (IHEX), external heat exchanger (EHEX), condensing heat exchanger (CHEX), Interface heat exchangers (InHEX), regenerative heat exchanger (RHEX) and compact heat exchangers (CoHEX), change, manipulate and optimize their configurations in piping and instrumentation diagrams (PIDs). In this short narrative, an effort has been made to summarize them, and their developments over time with a focus on the application, design, manufacturing, materials, and performance (in service and final operation).

Rare earths are classified as most important and critical material for US economy and defense by Congress and a mandate has been set to increase their in-house production, domestic resource utilization and decrease reliance on foreign resources and reserves. They are widely available in earth crust as ore (bastnaesite (La, Ce)FCO₃, monazite, (Ce, La, Y, Th)PO₄, and xenotime, YPO₄), but their so-called economic reserves are sparsely located geographically. They may be produced by various means such as beneficiation (physical, chemical, mechanical, or electrical), reduction (direct or indirect), electrolysis (of aqueous or molten / fused single or mixed salt systems) at high temperature or hydrometallurgy. Out of these, direct reduction also known as metallothermic reduction (La and Ca reduction) is mostly utilized. Its variant, high temperature electrowinning of fused salts is also practiced widely. These processes are material and application specific. In this study, author will employ thermodynamics (Ellingham diagrams, free energy of formation, reduction potential, Nernst equation, Pourbaix (E_h-pH) diagrams, E-pO^-2 diagrams), kinetics and energetic of a chemical reaction (chemical metallurgy) to reduce rare earth oxide / salt to rare earth metals (REO/RES – REM). It is shown that materials and energy requirement vary greatly depending on type of mineral ore, production facility, and beneficiation / mineral processing method selected. Aim is to reduce dependence on coal deposits. It is anticipated this route will be able to produce rare earths with > 35% yield and > 98% purity which be described in subsequent studies and patents.

Metallic glass matrix composites are unique new materials which have superior mechanical properties as compared to existing conventional materials. Owing to this, they are potential candidates for various future structural applications. However, they suffer from disadvantages of brittleness, poor ductility and little or no toughness and they manifest catastrophic failure on application of force. Their behavior is dubious and require extensive experimentation to draw conclusive results. In present study, which is continuation of previous study by author, an effort has been made to overcome this pitfall by simulation. A quantitative mathematical model based on KGT theory has been developed to describe nucleation and growth of crystalline phase dendrites in glassy matrix during solidification. It yields information about numerical parameters to understand the behavior of each individual element in a phase in multicomponent sluggish slurry and their effect on final microstructural evolution. Model is programmed and simulated in MATLAB®. Its validation is done by comparison with identical curves reported in literature previously for similar alloys. Results indicate that effect of incorporating all heat transfer coefficients at macroscopic level and diffusion coefficients at microscopic level play a vital role in refining the model and bringing it closer to actual experimental observations. Two types of hypoeutectic and eutectic systems namely Zr₆₅Cu₁₅Al₁₀Ni₁₀ and Zr_47.5Cu_45.5Al₅Co₂ respectively were studied. Simulation results were found to be in good agreement with prior simulated and experimental values

Development of rovers and development of infrastructure which enables them to probe other planets (such as Mars) have sparked a lot of interest recently specially with increasing public attention in Moon and Mars program by National Aeronautics and Space Administration. This is designed to be achieved by various means such as advanced spectroscopy and artificial intelligent techniques such as deep learning and transfer learning to enable the rover to not only map the surface of planet but to get a detailed information about its chemical makeup in layers beneath (deep learning) and in areas around point of observation (transfer learning). In this work, which is part of a proposal, later approach is explored. A systematic strategy is presented which make use of aforementioned techniques developed for metallic glass matrix composites as benchmark and helps develop algorithms for chemistry mapping of actual Martian surface on Perseverance Rover launching shortly.

Bulk metallic glass matrix composites have emerged as competent structural material of future bearing potential structural applications. However, the optimum percentage of crystallinity required to produce enough toughness that it can serve as structural component is still a matter of debate. In this study, an effort is made to address this problem by inoculation. A controlled amount of carefully selected inoculant is introduced in Zr_47.5Cu_45.5Al₅Co₂ bulk metallic glass matrix composite during melting and solidification. Its effect in promoting crystallinity is checked by detailed electron back scatter diffraction (EBSD) mapping. Proper pattern capture, background correction, binning, Hough space transformation, step size selection, indexing and matching with well-defined crystal structure files have shown to reflect upon map quality. This shows and bears direct relation with effect of inoculation. Results from two independent laboratories are reported. Inoculation treatment is shown to be advantageous.

Hydrothermal /super critical processes are important process to synthesize materials which are otherwise difficult to form under normal conditions. A mathematical model is developed using standard transport equations to calculate the time for heating of hydrothermal reactor and computer simulation of the model was carried out in SOLIDWORKS® to validate it. The materials used to form reactor vessel were stainless steel (outer body) and TEFLON (PFA) (inner vessel). It was shown that composite wall, its geometry, construction & properties greatly affect the time and pattern of heat transfer. The time calculated and pattern generated were found to be in good agreement with experimental values.