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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Orbital foamed material extruder

This invention is a process for producing foamed material in space comprising the steps of: rotating the material to simulate the force of gravity; heating the rotating material until it is molten; extruding the rotating, molten material; injecting gas into the extruded, rotating, molten material to produce molten foamed material; allowing the molten foamed material to cool to below melting temperature to produce the foamed material. The surface of the extruded foam may be heated to above melting temperature and allowed to cool to below melting temperature. The extruded foam may also be cut to predetermined length. The starting material may be metal or glass. Heating may be accomplished by electrical heating elements or by solar heating.

Tucker, Dennis S.↗
NASA NTRS2017

Systems and Methods for Fabricating Objects Including Amorphous Metal Using Techniques Akin to Additive Manufacturing

Systems and methods in accordance with embodiments of the invention fabricate objects including amorphous metals using techniques akin to additive manufacturing. In one embodiment, a method of fabricating an object that includes an amorphous metal includes: applying a first layer of molten metallic alloy to a surface; cooling the first layer of molten metallic alloy such that it solidifies and thereby forms a first layer including amorphous metal; subsequently applying at least one layer of molten metallic alloy onto a layer including amorphous metal; cooling each subsequently applied layer of molten metallic alloy such that it solidifies and thereby forms a layer including amorphous metal prior to the application of any adjacent layer of molten metallic alloy; where the aggregate of the solidified layers including amorphous metal forms a desired shape in the object to be fabricated; and removing at least the first layer including amorphous metal from the surface.

Hofmann, Douglas↗
NASA NTRSDate not supplied

Marangoni effect and its potential utilization in supporting lunar habitats and other extraterrestrial endeavors

Tears of wine is a phenomenon frequently observed as a ring of wine formed near the top of the glass generates droplets that fall back into the wine. This phenomenon can be explained by the Marangoni effect driven by the surface tension created via gradient on concentration and temperature along with the interface between two phases. Besides being observed while drinking wine, the Marangoni effect is crucial for welding metals, manufacturing integrated circuits, and growing crystals; the Marangoni effect might be also crucial in supporting lunar habitats and other extraterrestrial endeavors as vacuum and reduced gravity are expected to augment the Marangoni effect on extraterrestrial molten soil leading to sustainable extraterrestrial in-situ resources utilization (ISRU). Preliminary Marangoni effect assessment on molten lunar regolith was conducted via JSC-1A lunar regolith simulant under vacuum yielding a spontaneous upwards migration of a uniform molten thin-film front that climbed the crucible wall covering the entire wall’s surface and reaching the crucible’s top end. A temperature gradient within the melt’s bulk and along the crucible’s wall generates a surface tension large enough not only to form a meniscus within the three-phase junction (crucible’s wall, bulk melt, and vacuum) but also to supersede the gravitational force to create the upwards migration of a thin film front originated on the meniscus. The observed extensive wettability of the melt with the crucible surface, an additional key factor besides surface tension necessary to sustain upwards migration, is atypical to what it has been witnessed on molten JSC-1A lunar regolith simulant under non-vacuum conditions and smaller sample sizes. The unique formation and self-migration of a thin-film front could enable key ISRU processes such as thin-film coating, crystal growth, and feedstock generation for additive 3D printing. Further assessment on the higher-temperature vacuum-driven decomposition of the uniform thin-film front as it climbed the crucible’s wall revealed a significant decomposition of various simulant’s metal-oxide components into their respective oxygen and metal elements strengthening the feasibility of extraterrestrial generation and fractional separation of oxygen and metals/alloys with none or minimal need for terrestrial precursors. The Marangoni effect assessment on molten JSC-1A lunar regolith simulant clearly opens novel pathways in future extraterrestrial ISRU endeavors including manufacturing and mining. Extraterrestrial mining will require an operational approach completely different from the terrestrial one that heavily relies on not only mechanical excavation and transportation but also post-processing; an in-situ all-in-one process might be feasible via these two coupled phenomena, self-migration and decomposition.

J A Dominguez↗
NASA NTRS1982

The mechanisms of fine particle generation and electrification during Mount St. Helens volcanic eruption

Microscopical investigation of volcanic ash collected from ground stations during Mount St. Helens eruptions reveal a distinctive bimodel size distribution with high concentrations of particle ranges at (1) 200-100 microns and (2) 20-0.1 microns. Close examination of individual particles shows that most larger ones are solidified magma particles of porous pumice with numerous gas bubbles in the interior and the smaller ones are all glassy fragments without any detectable gas bubbles. Elemental analysis demonstrates that the fine fragments all have a composition similar to that of the larger pumice particles. Laboratory experiments suggest that the formation of the fine fragments is by bursting of glassy bubbles from a partially solidified surface of a crystallizing molten magma particle. The production of gas bubbles is due to the release of absorbed gases in molten magma particles when solubility decreases during phase transition. Diffusion cloud chamber experiments strongly indicate that sub-micron volcanic fragments are highly hygroscopic and extremely active as cloud condensation nuclei. Ice crystals also are evidently formed on those fragments in a supercooled (-20 C) cloud chamber. It has been reported that charge generation from ocean volcanic eruptions is due to contact of molten lava with sea water. This seems to be insufficient to explain the observed rapid and intense lightning activities over Mount St. Helens eruptions. Therefore, a hypothesis is presented here that highly electrically charged fine solid fragments are ejected by bursting of gas bubbles from the surface of a crystallizing molten magma particles.

Cheng, R. J.↗
NASA NTRS1982

Method and apparatus for producing gas-filled hollow spheres

A system for forming hollow spheres containing pressured gas is described which includes a cylinder device containing a molten solid material with a nozzle at its end. A second gas nozzle, lying slightly upstream from the tip of the first nozzle, is connected to a source that applies pressured filler gas that is to fill the hollow spheres. High pressure is applied to the molten metal, as by moving a piston within the cylinder device, to force the molten material out of the first nozzle. At the same time, pressured gas fills the center of the extruded hollow liquid pipe that breaks into hollow spheres. The environment outside the nozzles contains gas at a high pressure such as 100 atmospheres. Gas is supplied to the gas nozzle at a slightly higher pressure such as 101 atmospheres. The pressure applied to the molten material is at a still higher pressure such as 110 atmospheres.

Wang, T. G.↗
NASA NTRS1985

Float Zone Experiments in Space

The objective of this work has been to evaluate whether or not Marangoni flow could be suppressed in molten metals by the presence of very thin oxide films. Experimental work has been carried out on molten Sn under UHV conditions. A disk floating zone arrangement was developed to allow in situ Auger examination of molten surfaces. An electron energy loss technique was developed which allows detection of continuous tin oxide films of 6 A or greater. Experiments were planned to detect the effects of oxide formation upon Marangoni flow by measuring: (1) temperature profiles, (2) solid liquid interface shapes, (3) macrosegregation, and (4) the onset of oscillatory Marangoni flow by detecting oscillating temperature variations. Work on (4) showed that oscillatory temperature variations of frequency or = 10 Hz were not present in the disk float zone geometry under conditions of Ma = 4300 with an oxide free molten surface. The disk float zone geometry was modeled with a finite element analysis and temperature and velocity profiles were determined.

Verhoeven, J. D.↗
NASA NTRS1990

Copper Chloride Cathode For Liquid-Sodium Cell

Rechargeable liquid-sodium cell with copper chloride cathode offers substantial increase in energy density over cells made with other cathode materials. Unit has theoretical maximum energy density of 1135 W.h/kg. Generates electricity by electrochemical reaction of molten sodium and solid copper chloride immersed in molten electrolyte, sodium tetrachloroaluminate at temperature of equal to or greater than 200 degrees C. Wall of alumina tube separates molten electrolyte from molten sodium anode. Copper chloride cathode embedded in pores of sintered nickel cylinder or directly sintered.

Bugga, Ratnakumar V.↗
NASA NTRS1991

Analysis of lunar regolith thermal energy storage

The concept of using lunar regolith as a thermal energy storage medium was evaluated. The concept was examined by mathematically modeling the absorption and transfer of heat by the lunar regolith. Regolith thermal and physical properties were established through various sources as functions of temperature. Two cases were considered: a semi-infinite, constant temperature, cylindrical heat source embedded in a continuum of lunar regolith and a spherically shaped molten zone of lunar regolith set with an initial temperature profile. The cylindrical analysis was performed in order to examine the amount of energy which can be stored in the regolith during the day. At night, the cylinder acted as a perfect insulator. This cycling was performed until a steady state situation was reached in the surrounding regolith. It was determined that a cycling steady state occurs after approximately 15 day/night cycles. Results were obtained for cylinders of various diameters. The spherical molten zone analysis was performed to establish the amount of thermal energy, within the regolith, necessary to maintain some molten material throughout a nighttime period. This surrounding temperature profile was modeled after the cycling steady state temperature profile established by the cylindrical analysis. It was determined that a molten sphere diameter of 4.76 m is needed to maintain a core temperature near the low end of the melting temperature range throughout one nighttime period.

Colozza, Anthony J.↗
NASA NTRS1992

Edge-defined contact heater apparatus and method for floating zone crystal growth

An apparatus for growing a monocrystalline body (30) from a polycrystalline feed rod (22) includes a heater (20) that is positioned to heat a short section of the polycrystalline rod (22) to create a molten zone (34). The heater (20) is formed to include a shaper (40) that contacts the polycrystalline rod (22) in the molten zone (34) and has a hole (46) to allow flow in the molten zone (34) between the polycrystalline rod (22) side and the monocrystalline body (30) side of the shaper. The shaper (40) has an edge (42) that defines the boundary of the cross-section of the monocrystalline body (30) that is formed as the molten material solidifies.

Kou, Sindo↗
NASA NTRS2010

The Reduction of Lunar Regolith by Carbothermal Processing Using Methane

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source so that a small zone of molten regolith is established. A continuous flow of methane is maintained over the molten regolith zone. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. It is further processed downstream to ultimately produce oxygen.

Balasubramaniam, R.↗
NASA NTRS2010

The Reduction of Lunar Regolith by Carbothermal Processing Using Methane

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans Currently being developed by NASA. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source so that a small zone of molten regolith is established. A continuous flow of methane is maintained over the molten regolith zone. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. It is further processed downstream to ultimately produce oxygen.

Balasubramaniam, R.↗
NASA NTRS2013

Use of beam deflection to control an electron beam wire deposition process

A method for controlling an electron beam process wherein a wire is melted and deposited on a substrate as a molten pool comprises generating the electron beam with a complex raster pattern, and directing the beam onto an outer surface of the wire to thereby control a location of the wire with respect to the molten pool. Directing the beam selectively heats the outer surface of the wire and maintains the position of the wire with respect to the molten pool. An apparatus for controlling an electron beam process includes a beam gun adapted for generating the electron beam, and a controller adapted for providing the electron beam with a complex raster pattern and for directing the electron beam onto an outer surface of the wire to control a location of the wire with respect to the molten pool.

Taminger, Karen M.↗
NASA NTRS2017

Cavity Pull Rod: Device to Promote Single Crystal Growth from the Melt

A pull rod for use in producing a single crystal from a molten alloy is provided that includes an elongated rod having a first end and a second end, a first cavity defined at the first end and a second cavity defined at the first end and in communication with the first cavity. The first cavity receives the molten alloy and the second cavity vents a gas from the molten alloy to thereby template a single crystal when the pull rod is dipped into and extracted from the molten alloy.

Goldsby, Jon↗
NASA NTRS2017

Height Control and Deposition Measurement for the Electron Beam Free Form Fabrication (EBF3) Process

A method of controlling a height of an electron beam gun and wire feeder during an electron freeform fabrication process includes utilizing a camera to generate an image of the molten pool of material. The image generated by the camera is utilized to determine a measured height of the electron beam gun relative to the surface of the molten pool. The method further includes ensuring that the measured height is within the range of acceptable heights of the electron beam gun relative to the surface of the molten pool. The present invention also provides for measuring a height of a solid metal deposit formed upon cooling of a molten pool. The height of a single point can be measured, or a plurality of points can be measured to provide 2D or 3D surface height measurements.

Seufzer, William J.↗
NASA NTRS2022

Vacuum Melt Infiltration of 2D Tyranno SA3® Ceramic Matrix Composites with Cr-25(wt.%)Si Intermetallic Alloy

The potential and limitations of vacuum melt infiltrating woven preforms of 2D Tyranno SA3 fibers with Cr-25(wt.%)Si alloy were investigated. Microstructural observations revealed that the volume fractions of open voids infiltrated by the molten metal varied between 3.7 and 10.0% irrespective of the magnitudes of the melt infiltration temperatures and hold times, which was attributed in part to substantial volatilization of the silicide charge based on computational thermodynamics. In the absence of experimental data, poor wettability of the melt could not be ruled out unambiguously. Other possible reasons are carefully examined and discarded. Ring microstructures were observed around the fibers mainly at the outer surfaces of the infiltrated preform, where the BN and chemical vapor infiltrated SiC coatings had vaporized in the high vacuum environment. In contrast, they were absent in the interior of the preform, where the coatings were still present with no evidence of molten metal attack of the coatings. Details of thermodynamic calculations are presented to confirm the volatilization of the BN and CVI SiC coatings thereby resulting in the ring microstructures due to the filling of voids by the molten silicide. It is concluded that successful melt infiltration of Tyranno SA3® with Cr-25%Si can be only achieved under sufficient positive pressure to prevent volatilization of the coatings and the molten silicide.

Cr-25%Si↗
NASA NTRSDate not supplied

Advanced Metal Separation (AMS) via Marangoni Effect-driven Separation

For practical, economical, and sustainable human missions to the Moon, processing of lunar regolith and metal oxides is necessary for localized production of oxygen (O2) and metals that can be repurposed as rocket propellant, life support O2, and in-space manufactured parts. The primary candidates for in-situ resource utilization (ISRU) regolith processing are carbothermic reductions and molten regolith electrolysis (MRE) which both produce oxygen and a reduced, deoxygenated metallic slag. A metal separation technique is still required to capture and purify metals from the deoxygenated slag for reuse in areas such as metallic part fabrication, structural or design frameworks, and metal catalyst production. The Marangoni Effect is best explained as mass transfer along an interface driven by surface tension gradients induced by temperature and concentration differences. Due to the temperature gradients, molten metal can be transported in this fashion to create thin films. This method can transport molten metal in the absence of gravity or mechanical motion and greatly increases the available surface area for a vacuum fractional separation process. In this study, a novel vacuum furnace induces the Marangoni Effect to fractionally decompose and separate valuable metals (e.g., aluminum) from thin films of molten metal via vacuum distillation. The proposed work will examine lunar regolith, metal-based recycling feedstocks, and metallic slags produced from the carbothermal reduction of regolith. Data and observations from this study could produce a simple yet effective method of refining lunar derived metals by taking advantage of the high vacuum environment present on the lunar surface.

ISRU↗
NASA NTRSDate not supplied

Exploring the Effect of EBC Composition on CMAS Wetting Behavior

Rare-earth disilicate (REDS) materials are existing materials used in environmental barrier coating (EBC) for the protection of structural materials in the hot-section of turbine engines. REDS interactions with molten calcium-magnesium-aluminosilicate (CMAS) debris are of interest to understand molten CMAS attack and improve CMAS mitigation strategies. This work assesses the effect of REDS composition on CMAS wetting by investigating wetting angle, spreading, and reactivity. Freestanding atmospheric plasma spray (APS) REDS coatings (for RE = Y, La, Nd, Gd, Yb, Lu) were exposed to 10 mg of CMAS (Ca33-Mg9-Al13-Si45 in single cation mol%) in stagnant lab air at 1250C. APS YbDS was compared to a dense spark plasma sintered (SPS) phase-pure Yb2Si2O7 and a nominal 20 vol% phase-mixture of Yb 2 SiO 5 in Yb 2 Si 2 O 7 (20YbMS/YbDS). CMAS mass was held constant but specimen surface areas varied, yielding a range of loading between ~6 and 10 mg/cm2. CMAS was loaded as a cylindrical rod atop the specimen surface, polished to 4000 grit, and heated to temperature in a Linseis L74/HS/1700 heating microscope. The heating microscope measured the evolution of molten CMAS diameter, height, and contact angle. Molten CMAS diameter at 1150C and contact angle measurements after two hours of exposure at 1250C yielded a positive trend with rare-earth cation size. There was no statistically significant difference in CMAS wetting behavior between SPS YbDS and 20YbMS/YbDS. Post-exposure specimens were examined in plan view and cross-section with XRD, SEM, and EDS. CMAS spreading was cross-examined using plan view SEM, while reactivity utilized plan view XRD and cross-sectional SEM/EDS.

Clark Luckhardt↗
NASA NTRS2024

Mechanisms of Apatite Formation in Reactions of Yb 2-2x Gd 2x Si 2 O 7 with CMAS

Bulk β-Yb 1.9 Gd 0.1 Si 2 O 7 , β-Yb 1.6 Gd 0.4 Si 2 O 7 , and γ-Yb 1.4 Gd 0.6 Si 2 O 7 , along with baseline γ-Y 2 Si 2 O 7 and β-Yb 2 Si 2 O 7 were investigated in contact with a molten silicate to determine mechanisms of thermochemical degradation. A model 30.67CaO-8.25MgO-12.81AlO 1.5- 48.27SiO 2 silicate composition was deposited on the surfaces of the samples at a loading of ~2 mg/cm 2 . Reactions with the molten silicate resulted in the formation of a silicate apatite layer, which has been shown to reduce further molten silicate infiltration. Additions of gadolinium up to 30 mol% to Yb 2 Si 2 O 7 reduced infiltration up to ~60% compared to baseline Yb 2 Si 2 O 7 , but additional exposure time at temperature resulted in loss of the apatite layer. The results herein indicate that doping with gadolinium disilicate may not be beneficial in the long term degradation of disilicate-based EBCs by molten silicates.

Jamesa L. Stokes↗