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At least 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Compact, Lightweight Electromagnetic Pump for Liquid Metal

A proposed direct-current electromagnetic pump for circulating a molten alkali metal alloy would be smaller and lighter and would demand less input power, relative to currently available pumps of this type. (Molten alkali metals are used as heat-transfer fluids in high-temperature stages of some nuclear reactors.) The principle of operation of this or any such pump involves exploitation of the electrical conductivity of the molten metal: An electric current is made to pass through the liquid metal along an axis perpendicular to the longitudinal axis of the flow channel, and a magnetic field perpendicular to both the longitudinal axis and the electric current is superimposed on the flowchannel region containing the electric current. The interaction between the electric current and the magnetic field produces the pumping force along the longitudinal axis. The advantages of the proposed pump over other such pumps would accrue from design features that address overlapping thermal and magnetic issues.

Godfroy, Thomas↗
NASA NTRS2010

Economical Fabrication of Thick-Section Ceramic Matrix Composites

A method was developed for producing thick-section [>2 in. (approx.5 cm)], continuous fiber-reinforced ceramic matrix composites (CMCs). Ultramet-modified fiber interface coating and melt infiltration processing, developed previously for thin-section components, were used for the fabrication of CMCs that were an order of magnitude greater in thickness [up to 2.5 in. (approx.6.4 cm)]. Melt processing first involves infiltration of a fiber preform with the desired interface coating, and then with carbon to partially densify the preform. A molten refractory metal is then infiltrated and reacts with the excess carbon to form the carbide matrix without damaging the fiber reinforcement. Infiltration occurs from the inside out as the molten metal fills virtually all the available void space. Densification to <5 vol% porosity is a one-step process requiring no intermediate machining steps. The melt infiltration method requires no external pressure. This prevents over-infiltration of the outer surface plies, which can lead to excessive residual porosity in the center of the part. However, processing of thick-section components required modification of the conventional process conditions, and the means by which the large amount of molten metal is introduced into the fiber preform. Modification of the low-temperature, ultraviolet-enhanced chemical vapor deposition process used to apply interface coatings to the fiber preform was also required to accommodate the high preform thickness. The thick-section CMC processing developed in this work proved to be invaluable for component development, fabrication, and testing in two complementary efforts. In a project for the Army, involving SiC/SiC blisk development, nominally 0.8 in. thick x 8 in. diameter (approx. 2 cm thick x 20 cm diameter) components were successfully infiltrated. Blisk hubs were machined using diamond-embedded cutting tools and successfully spin-tested. Good ply uniformity and extremely low residual porosity (<2 percent) were achieved, the latter being far lower than that achieved with SiC matrix composites fabricated via CVI or PIP. The pyrolytic carbon/zirconium nitride interface coating optimized in this work for use on carbon fibers was incorporated in the SiC/SiC composites and yielded a >41 ksi (approx. 283 MPa) flexural strength.

Babcock, Jason↗
NASA NTRS2012

Modeling of Melt Growth During Carbothermal Processing of Lunar Regolith

The carbothermal processing of lunar regolith has been proposed as a means to produce carbon monoxide and ultimately oxygen to support human exploration of the moon. In this process, gaseous methane is pyrolyzed as it flows over the hot surface of a molten zone of lunar regolith and is converted to carbon and hydrogen. Carbon gets deposited on the surface of the melt, and mixes and reacts with the metal oxides in it to produce carbon monoxide that bubbles out of the melt. Carbon monoxide is further processed in other reactors downstream to ultimately produce oxygen. The amount of oxygen produced crucially depends on the amount of regolith that is molten. In this paper we develop a model of the heat transfer in carbothermal processing. Regolith in a suitable container is heated by a heat flux at its surface such as by continuously shining a beam of solar energy or a laser on it. The regolith on the surface absorbs the energy and its temperature rises until it attains the melting point. The energy from the heat flux is then used for the latent heat necessary to change phase from solid to liquid, after which the temperature continues to rise. Thus a small melt pool appears under the heated zone shortly after the heat flux is turned on. As time progresses, the pool absorbs more heat and supplies the energy required to melt more of the regolith, and the size of the molten zone increases. Ultimately, a steady-state is achieved when the heat flux absorbed by the melt is balanced by radiative losses from the surface. In this paper, we model the melting and the growth of the melt zone with time in a bed of regolith when a portion of its surface is subjected to a constant heat flux. The heat flux is assumed to impinge on a circular area. Our model is based on an axisymmetric three-dimensional variation of the temperature field in the domain. Heat transfer occurs only by conduction, and effects of convective heat transport are assumed negligible. Radiative heat loss from the surface of the melt and the regolith to the surroundings is permitted. We perform numerical computations to determine the shape and the mass of the melt at steady state and its time evolution. We first neglect the volume change upon melting, and subsequently perform calculations including it. Predictions from our model are compared to test data to determine the effective thermal conductivities of the regolith and the melt that are compatible with the data

Balasubramaniam, R.↗
NASA NTRS2014

GRAIL Refinements to Lunar Seismic Structure

Gravity field measurements are perhaps the most numerous of the indirect observations relevant to the Moon's internal structure. Multiple recent missions have mapped the global lunar gravity field, each one improving upon the resolution of the last. The details of the Moon's deepest structure, including the parameters that define the lunar core, however, were still largely unaddressed by pre-GRAIL gravity measurements, which were not high enough resolution to resolve the tidal coefficients at a sufficient degree of accuracy. Current constraints on core size and state arise from other indirect measurements, including lunar laser ranging, magnetic induction studies, and analyses of elemental abundances in depth-derived mare basalts. These inferences vary widely, but when considered together with structure models derived from the seismic data gathered during the Apollo missions, a schematic of the lunar interior containing a partially molten deepest mantle layer overlying molten outer and solid inner core layers was obtained. Seismology provides the most direct constraints on the variables that govern the dynamic properties of the body. However, the GRAIL mission's high-resolution measurements of the lunar gravity field are being used to constrain the interior structure of the Moon using a "crust to core" approach. GRAIL's constraints on crustal thickness, mantle structure, core radius and stratification, and core state (solid vs. molten) therefore complement seismic investigations. This work focuses on expanding our knowledge of the Moon's internal structure using joint gravity and seismic analyses, which will improve constraints on the deep lunar mantle and core.

Weber, Renee C.↗
NASA NTRS2015

Determination of the Contact Angle Based on the Casimir Effect

In several crystal growth processed based on capillarity, a melt comes into contact with a crucible wall at an angle defined as the contact angle. For molten metals and semiconductors, this contact angle is dependent upon both the crucible and melt material and typical values fall in the range 80-170deg. However, on a microscopic scale, there does not exist a precise and sharp contact angle but rather the melt and solid surfaces merge smoothly and continuously over a distance of up to several micrometers. Accurate modeling requires a more advanced treatment of this interaction. The interaction between the melt and solid surfaces can be calculated by considering two forces: a short-range repulsive force and a longer range (up to a few micrometers) Casimir force. The Casimir force between the two bodies of complex geometry is calculated using a retarded temperature Green's function (Matsubara type) for the photon in the medium. The governing equations are cast in the form of a set of boundary integral equations which are then solved numerically for the case of molten Ge on SiO2. The shape of the molten surface approaching the flat solid body is determined, and the contact angle is defined as the angle between the two surfaces at the microscopically asymptotic distance of 1-2 micrometers. The formulation of this model and the results of the numerical calculations will be presented and discussed.

Mazuruk, K.↗
NASA NTRS2018

Systems and Methods for Fabricating Structures Including Metallic Glass-Based Materials Using Low Pressure Casting

Systems and methods to fabricate objects including metallic glass-based materials using low-pressure casting techniques are described. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: introducing molten alloy into a mold cavity defined by a mold using a low enough pressure such that the molten alloy does not conform to features of the mold cavity that are smaller than 100 microns; and cooling the molten alloy such that it solidifies, the solid including a metallic glass-based material.

Hofmann, Douglas C.↗
NASA NTRSDate not supplied

The Effects of Arcing Ejecta on Space Suit Materials from ISS RPCM Hot Mate/Demate During EVA

Onboard ISS, taking systems off-line when powering down to perform servicing on Remote Power Control Modules (RPCMs) introduces operational risk. An investigation lead by the NASA Engineering and Safety Center (NESC) was performed by a multi-center team to assess the safety of performing on-orbit replacement of RPCMs without powering down. This investigation revealed the potential for molten metal particulate generation in the event of an arcing occurrence. As RPCM replacement can be performed outside ISS during an Extra Vehicular Activity (EVA), it is necessary to assess the effects of this molten metal ejecta contact with the Extravehicular Mobility Unit (EMU) Space Suit Assembly (SSA) during an arcing event. A test was devised to mimic arcing ejecta contact with samples representing various SSA cross-sections. Four areas of the SSA were chosen for test to represent the majority of the SSA cross-sections. Testing was conducted by the University of California, Riverside that generated the molten metal particles, included varying composition, size and temperature, and dropped them onto the surface of the various SSA cross-sections. Exposed SSA materials were then evaluated for degree of damage, penetration, and thermal conductance through the cross-section by ILC Dover. Results showed that the SSA Glove is most susceptible to damage from arcing events. This data will be used to make risk management decisions for future RPCM servicing operations. This testing also demonstrated the durability of the SSA design and materials to exposure to extreme environments

Linda S Hewes↗
NASA NTRSDate not supplied

The Effects of Arcing Ejecta on Space Suit Materials from ISS RPCM Hot Mate/Demate During EVA

Onboard ISS, taking systems off-line when powering down to perform servicing on Remote Power Control Modules (RPCMs) introduces operational risk. An investigation lead by the NASA Engineering and Safety Center (NESC) was performed by a multi-center team to assess the safety of performing on-orbit replacement of RPCMs without powering down. This investigation revealed the potential for molten metal particulate generation in the event of an arcing occurrence. As RPCM replacement can be performed outside ISS during an Extra Vehicular Activity (EVA), it is necessary to assess the effects of this molten metal ejecta contact with the Extravehicular Mobility Unit (EMU) Space Suit Assembly (SSA) during an arcing event. A test was devised to mimic arcing ejecta contact with samples representing various SSA cross-sections. Four areas of the SSA were chosen for test to represent the majority of the SSA cross-sections. Testing was conducted by the University of California, Riverside that generated the molten metal particles, included varying composition, size and temperature, and dropped them onto the surface of the various SSA cross-sections. Exposed SSA materials were then evaluated for degree of damage, penetration, and thermal conductance through the cross-section by ILC Dover. Results showed that the SSA Glove is most susceptible to damage from arcing events. This data will be used to make risk management decisions for future RPCM servicing operations. This testing also demonstrated the durability of the SSA design and materials to exposure to extreme environments.

Linda S. Hewes↗
NASA NTRS1966

Jig protects transistors from heat while tinning leads

In tinning transistor leads, an aluminum jig is used to dip the leads into the molten tin. The jigs mass shunts excess heat given off by the molten tin before it reaches and damages the transistor body.

Pelletier, A. J.↗
NASA NTRS1972

Effects of normal acceleration on transient burning rate augmentation of an aluminized solid propellant

Instantaneous burning rate data for a polybutadiene acrylic acid propellant, containing 16 weight percent aluminum, were calculated from the pressure histories of a test motor with 96.77 sq cm of burning area and a 5.08-cm-thick propellant web. Additional acceleration tests were conducted with reduced propellant web thicknesses of 3.81, 2.54, and 1.27 cm. The metallic residue collected from the various web thickness tests was characterized by weight and shape and correlated with the instantaneous burning rate measurements. Rapid depressurization extinction tests were conducted in order that surface pitting characteristics due to localized increased burning rate could be correlated with the residue analysis and the instantaneous burning rate data. The acceleration-induced burning rate augmentation was strongly dependent on propellant distance burned, or burning time, and thus was transient in nature. The results from the extinction tests and the residue analyses indicate that the transient rate augmentation was highly dependent on local enhancement of the combustion zone heat feedback to the surface by the growth of molten residue particles on or just above the burning surface. The size, shape, and number density of molten residue particles, rather than the total residue weight, determined the acceleration-induced burning rate augmentation.

Northam, G. B.↗
NASA NTRS1971

Irradiation of linear polyethylene - Partitioning between sol and gel.

Molecular weight fractions of linear polyethylene were irradiated at 133 C, in the completely molten and highly crystalline states, for the purpose of assessing the importance of chain-scission processes and establishing the critical conditions for gelation. The partitioning between sol and gel in either state was found to adhere to the theory for the intermolecular cross-linking of monodisperse species for dosages just beyond the gel point. Deviations from theory occurred as the dosage was increased further. It was concluded that main-chain scission, at these temperatures, is not a significant process. High molecular weight samples in the completely molten state obeyed the Flory-Stockmayer condition for critical gelation.

Rijke, A. M.↗
NASA NTRS1973

Droplet breakup in accelerating gas flows. Part 1: Primary atomization

An experimental study of the effects of an accelerating gas flow on the atomization characteristics of liquid sprays was conducted. The sprays were produced by impinging two liquid jets. The liquid was molten wax, while the gas was nitrogen. The use of molten wax allowed for a quantitative measure of the resulting dropsize distribution. The effects of the accelerating gas flow on the formation of the spray were examined. The results of this study indicate that the parameters that most affect the resulting dropsize are the injector parameters of orifice diameter and injection velocity, the maximum gas velocity, and the distance from the injector face at which the maximum gas velocity is attained. Empirical correlations for both the mass median dropsize and the dropsize distribution are presented. These correlations can be readily incorporated into existing computer codes for the purpose of calculating rocket engine combustion performance.

Zajac, L. J.↗
NASA NTRS1973

Droplet breakup in accelerating gas flows. Part 2: Secondary atomization

An experimental investigation to determine the effects of an accelerating gas flow on the atomization characteristics of liquid sprays was conducted. The sprays were produced by impinging two liquid jets. The liquid was molten wax and the gas was nitrogen. The use of molten wax allowed for a quantitative measure of the resulting dropsize distribution. The results of this study, indicate that a significant amount of droplet breakup will occur as a result of the action of the gas on the liquid droplets. Empirical correlations are presented in terms of parameters that were found to affect the mass median dropsize most significantly, the orifice diameter, the liquid injection velocity, and the maximum gas velocity. An empirical correlation for the normalized dropsize distribution is also presented. These correlations are in a form that may be incorporated readily into existing combustion model computer codes for the purpose of calculating rocket engine combustion performance.

Zajac, L. J.↗
NASA NTRS1973

Moon - 'Ghost' craters formed during Mare filling.

This paper discusses formation of 'pathological' cases of crater morphology due to interaction of craters with molten lavas. Terrestrial observations of such a process are discussed. In lunar maria, a number of small impact craters (D less than 10 km) may have been covered by thin layers of fluid lavas, or formed in molten lava. Some specific lunar examples are discussed, including unusual shallow rings resembling experimental craters deformed by isostatic filling.

Cruikshank, D. P.↗
NASA NTRS1973

Research study on materials processing in space experiment M512

A study program was conducted to clarify the role of gravity in the fluid mechanics of certain molten metal processes of potential significance to manufacturing in space. In particular, analyses were conducted of the M551 Metals Melting Experiment and the M553 Sphere Forming Experiment to be conducted in the M512 Facility onboard Skylab. The M551 experiment consisted of a study of electron beam welding of various metals, and the M553 experiment studied the formation of molten metal spheres by free-floating in a near zero-gravity environment. The analyses of these experiments and a comparison with ground-based and KC135 experimental results are presented.

Brashears, M. R.↗
NASA NTRS1974

Skylab M551 Metals Melting Experiment

The objectives of the M551 Metals Melting Experiment are to (a) study behavior of molten metal, (b) characterize metals melted and solidified in the low gravity space environment compared to one-gravity of earth, and (c) determine feasibility of joining metals in space. The experiment used the electron beam (EB) and chamber of the M512 apparatus to make a dwell puddle and a melt in a rotating disc of varying thickness. Hence, the EB performed cut-through, full and partial penetration melts, in addition to a re-solidified button. The three disc materials were aluminum 2219-T87, 304 stainless steel and pure tantalum to provide a wide range of density and melting conditions. Observations to date include (a) the proof that EB welding, cutting and melting can be done successfully in low gravity. Earlier, some welding authorities had postulated that without gravity the EB would force the molten puddle out of contact. However, the experiment proved that surface tension forces predominate. (b) From the view-point of cast-solidification, small, equiaxed grains in Skylab specimens compared to large, elongated grains in ground-based specimens were observed. The former are thought to be associated with constitutional supercooling and nucleation where the latter are associated with dendritic solidification. In further support of the more equiaxed grain growth in Skylab, symmetric sub-grain patterns were frequently observed where there was much less symmetry in ground-based specimens. Further work is being done to explain the differences in solidification.

E C Mckannan↗
NASA NTRS1973

Research study on materials processing in space experiment M512

A study program was conducted to clarify the role of gravity in the fluid mechanics of certain molten metal processes of potential significance to manufacturing in space. In particular, analyses were conducted of the M551 Metals Melting Experiment and the M553 Sphere Forming Experiment to be conducted in the M512 Facility onboard Skylab. The M551 experiment consisted of a study of electron beam welding of various metals, and the M553 experiment studied the formation of molten metal spheres by free-floating in a near zero-gravity environment. The analyses of these experiments and a comparison with ground-based and KC135 experimental results are presented.

Brashears, M. R.↗