Preliminary design of a high temperature space manufacturing furnace
High temperature space manufacturing furnace for melting glass in orbital workshop
Sparks, V. W.↗
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Numerical and Experimental Study of Transport Phenomena in Directional Solidification of Succinonitrile
A numerical and experimental study of the growth of succinonitrile (SCN) using a horizontal Bridginan furnace and transparent glass ampoule was conducted. Two experiments were considered: one in which the temperature profile was fixed relative to the ampoule (no-growth case); and a second in which the thermal profile was translated at a constant rate (steady growth case). Measured temperature profiles on the outer surface of the ampoule were used as thermal boundary conditions for the modelling. The apparent heat capacity formulation combined with the variable viscositymeth~ was used to model the phase change in SeN. Both 2-D and 3-D models were studied and numerical solutions obtained using the commercial finite element code, FIDAP1. Comparison of the numerical results to experimental data showed excellent agreement. The complex 3-D shallow-cavity flow in the melt, differences between 2-D and 3-D models, effects of natural convection on the thermal gradient and shape of the solid/liquid interface, and the sensitivity of simulations to specific assumptions, are also discussed.
de Groh, Henry C., III↗
Making Highly Pure Glass Rods
Proposed quasi-containerless method for making glass rods or fibers minimizes contact between processing equipment and product. Method allows greater range of product sizes and shapes than achieved in experiments on containerless processing. Molten zone established in polycrystalline rod. Furnace sections separated, and glass rod solidifies between them. Clamp supports solid glass as it grows in length. Pulling clamp rapidly away from melt draws glass fiber. Fiber diameter controlled by adjustment of pulling rate.
Naumann, R. J.↗
Thermal Analysis Of Reluctant Glass Formers
Thermocouple holds sample and monitors temperature during cooling. Ellipsoidal furnace provides controlled cooling rates for studies of thermal properties of reluctant glass formers. Glass tube inserted into furnace and used to blow helium on specimen to cool rapidly. Cooling curve analyzed to determine rate of cooling and such properties of sample as nucleation and recalescence temperatures at cooling rate. Continuous-cooling-crystallization boundaries determined empirically from plots of nucleation time vs. nucleation temperature from runs at large number of different rates of cooling. Apparatus used to examine glass-formation ability of material and critical cooling rate to form glass.
Ethridge, Edwin C.↗
Containerless glass fiber processing
An acoustic levitation furnace system is described that was developed for testing the feasibility of containerless fiber pulling experiments. It is possible to levitate very dense materials such as platinum at room temperature. Levitation at elevated temperatures is much more difficult. Samples of dense heavy metal fluoride glass were levitated at 300 C. It is therefore possible that containerless fiber pulling experiments could be performed. Fiber pulling from the melt at 650 C is not possible at unit gravity but could be possible at reduced gravities. The Acoustic Levitation Furnace is described, including engineering parameters and processing information. It is illustrated that a shaped reflector greatly increases the levitation force aiding the levitation of more dense materials.
Ethridge, E. C.↗
STS-47 Mission Highlights Resource Tape
The mission of the STS-47 flight is highlighted in this video. The flight crew consisted of: Cmdr. 'Hoot' Gibson, Pilot Kurt Brown, Payload Cmdr. Jan Davis, Payload Specialist. M. Mohri (Japanese Astronaut), and Mission Specialists Jay Apt and May Jemison. The primary goal of this mission was the set-up and carrying out of experiments in the accompanying Japanese Spacelab (SL-J) in cooperation with the Japanese Space Program. Dr. Mohri is the first professional Japanese astronaut to fly in space. Vice President Dan Quayle and his wife are shown addressing the astronauts of the Space Shuttle Endeavour with a small pre-launch speech. On this flight many different physical, physiological, and biological spaceborne experiments were performed. These experiments included: a gas evaporation in low gravity environment experiment; a brainwave signals from carp experiment; several human eye movement and visual physiological tests; various physiological tests on a variety of insects and frogs; a embryology experiments on tadpoles; several experiments concerned with fluid dynamics; an imaging furnace test with heated glass containing gold particles (flow measurement); a Solid Surface Combustion Experiment; and a protein crystal growth experiment. Launch, in-orbit, and landing footage is shown, along with a variety of crew activities. One feature that astronauts were able to videotape was the actual in-orbit movement of the side wing flaps of the Space Shuttle.
Source record↗
Fiber glass pulling
Experiments were conducted to determine the viability of performing containerless glass fiber pulling in space. The optical transmission properties and glass-forming capabilities of the heavy metal fluorides are reviewed and the acoustic characteristics required for a molten glass levitation system are examined. The design limitations of, and necessary modifications to the acoustic levitation furnace used in the experiments are discussed in detail. Acoustic levitator force measurements were performed and a thermal map of the furnace was generated from thermocouple data. It was determined that the thermal capability of the furnace was inadequate to melt a glass sample in the center. The substitution of a 10 KW carbon monoxide laser for the original furnace heating elements resulted in improved melt heating.
Workman, Gary L.↗
Effects of Texture and Silica Content on Crack Growth in Boron Nitrides
Boron nitride is used in applications such as crucibles for melting and casting glasses and metals, insulators for furnaces, molds for hot pressing, and neutron absorbers. Historically, various grades of hot pressed hexagonal boron nitride (BN) have been used. This study investigates the fracture toughness and slow crack growth parameters of several commercially available BN grades. Prior work revealed that some grades of BN absorb water and change strength, thus presenting a philosophical conundrum on crack growth test methods. The grades selected for this study are of interest because their available billet size is sufficient for large components, or because they have heritage in specific applications. Ultimately, the data will be used to perform material selection, system design and reliability analyses of components of interest. Boron nitrides exhibit limited slow crack growth in humidity, with an orientation dependence due to crystallographic texture: orientations with van der Waal bonds are insensitive to water whereas those with covalent bonds are sensitive. Fracture toughness is low, around that of glass, and is also a function of orientation (bond type), with fracture occurring more readily along van der Waal bonds between hexagonal BN platelets than at covalent bonds across platelets. Silica additions toughen BN, but increase slow crack growth susceptibility.
Salem, Jonathan A.↗
Angular glass tubing drawn from round tubing
Round glass tubing softened in a furnace is drawn over a shaped plug or mandel to form shapes with other than a circular cross section. Irregularly shaped tubing is formed without limitations on tube length or wall thickness.
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Melting and Crystallization Behavior of CaO-MgO-Al2O3-SiO2 Silicates Relevant to Turbine Engine Applications
The melting and crystallization behavior of four quaternary CaO-MgO-Al2O3-SiO2(CMAS) silicates were investigated. The CaO:SiO2 ratios of these systems were based on various terrestrial sources of ingested particles relevant to gas turbine engine operating environments. Melting behavior was characterized using differential scanning calorimetry, and high temperature intrinsic crystallization products were determined by furnace heat treatments of the glasses at 1200°C, 1300°C, and 1400°C. The silicates exhibited a wide range of melting temperatures from ~1240°C up to ~1500°C, with most of the compositions exhibiting incongruent melting behavior. High temperature crystallization products included CaSiO3,CaAl2Si2O8, Ca2MgSi2O7, and Ca(Mg,Al)Si2O6, although SiO2 was the only crystalline phase observed at 1400°C.
Jamesa L. Stokes↗
A new method of efficient heat transfer and storage at very high temperatures
A unique, high temperature (1000-2000 K) continuously operating capacitive heat exchanger system is described. The system transfers heat from a combustion or solar furnace to a working gas by means of a circulating high temperature molten refractory. A uniform aggregate of beads of a glass-like refractory is injected into the furnace volume. The aggregate is melted and piped to a heat exchanger where it is sprayed through a counter-flowing, high pressure working gas. The refractory droplets transfer their heat to the gas, undergoing a phase change into the solid bead state. The resulting high temperature gas is used to drive a suitable high efficiency heat engine. The solidified refractory beads are delivered back to the furnace and melted to continue the cycle. This approach avoids the important temperature limitations of conventional tube-type heat exchangers, giving rise to the potential of converting heat energy into useful work at considerably higher efficiencies than currently attainable and of storing energy at high thermodynamic potential.
Shaw, D.↗
Melt-processing of lunar ceramics
The goal of this project is to produce useful ceramics materials from lunar resources using the by products of lunar oxygen production processes. Emphasis is being placed on both fabrication of a variety of melt-processed ceramics, and on understanding the mechanical properties of these materials. Previously, glass-ceramics were formed by casting large glass monoliths and heating these to grow small crystallites. The strengths of the resulting glass-ceramics were found to vary with the inverse square root of the crystal grain size. The highest strengths (greater than 300 MPa) were obtained with the smallest crystal sizes (less than 10 microns). During the past year, the kinetics of crystallization in simulated lunar regolith were examined in an effort to optimize the microstructure and, hence, mechanical properties of glass ceramics. The use of solar energy for melt-processing of regolith was examined, and strong (greater than 630 MPa) glass fibers were successfully produced by melt-spinning in a solar furnace. A study of the mechanical properties of simulated lunar glasses was completed during the past year. As on Earth, the presence of moisture was found to weaken simulated lunar glasses, although the effects of surface flaws was shown to outweigh the effect of atmospheric moisture on the strength of lunar glasses. The effect of atmospheric moisture on the toughness was also studied. As expected, toughness was found to increase only marginally in an anhydrous atmosphere. Finally, our efforts to involve undergraduates in the research lab fluorished this past year. Four undergraduates worked on various aspects of these projects; and two of them were co-authors on papers which we published.
Fabes, B. D.↗
Variation of Resin Properties Through the Thickness of Cured Samples
It is the purpose of this work to gain knowledge of the glassy materials used as matrices in composites and to study the homogeneity resulting from the curing process. An attempt is made to link the glass transition quantitatively with the presence of a given material. Expoxy resins containing various amounts of hardener (TGDDM/DDS system) were cured in a muffle furnace at 473 K for seven hours. The glass transition temperature, T sub g versus weight minus percent of hardener in the epoxy resin were measured. A limit was rapidly reached in T sub g at only two percent hardener. Thus, the glass transition of the fully cured epoxy-amine matrix seems not much different from the epoxide-epoxide cure. The T sub g versus cure-time for the epoxide-epoxide reaction was also studied. My 720 was cured by itself in an oil bath at 473 K for different lengths of time. The T sub g was found to increase exponentially with the cure time, and a maximum T sub g of about 450 K was reached after eleven hours. The reaction was found to be inhibited by running the sample under argon.
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Low Gravity Rapid Thermal Analysis of Glass
It has been observed by two research groups that ZrF4-BaF2-LaF3-AlF3-NaF (ZBLAN) glass crystallization is suppressed in microgravity. The mechanism for this phenomenon is unknown at the present time. In order to better understand the mechanism, an experiment was performed on NASA's KC135 reduced gravity aircraft to obtain quantitative crystallization data. An apparatus was designed and constructed for performing rapid thermal analysis of milligram quantities of ZBLAN glass. The apparatus employs an ellipsoidal furnace allowing for rapid heating and cooling. Using this apparatus nucleation and crystallization kinetic data was obtained leading to the construction of time-temperature-transformation curves for ZBLAN in microgravity and unit gravity.
Tucker, Dennis S.↗
Crystallization kinetics of a lithia-silica glass - Effect of sample characteristics and thermal analysis measurement techniques
DTA and both isothermal and nonisothermal DSC techniques are presently used to investigate the crystallization kinetics of a 40 (mol) percent Li2O-60 percent SiO2 glass as a function of glass powder particle size, the use of either alumina or Pt as the crucible material, the use of N, O, or Ar atmospheres, and surface pretreatments of the glass powder with deionized water, HCl, or HF. Neither the furnace atmosphere nor the crucible material had a significant effect on activation energy, frequency factor, or Avrami exponent. Washings of the glass with the three different fluids decreased the crystallization temperature by 25 to 30 C.
Ray, Chandra S.↗
New Fiber Reinforced Waterless Concrete for Extraterrestrial Structural Applications
Commercial use of sulfur concrete on Earth is well established, particularly in corrosive, e.g., acid and salt, environments. Having found troilite (FeS) on the Moon raises the question of using extracted sulfur as a lunar construction mate: iii an attractive alternative to conventional concrete as it does not require water For the purpose of this paper it is assumed that lunar ore is mined, refined, and the raw sulfur processed with appropriate lunar regolith to form, for example, brick and beam elements. Glass fibers produced from regolith were used as a reinforcement to improve the mechanical properties of the sulfur concrete. Glass fibers and glass rebar were produced by melting the lunar regolith simulant. Lunar regolith stimulant was melted in a 25 cc Pt-Rh crucible in a Sybron Thermoline 46100 high temperature MoSi2 furnace at melting temperatures of 1450 to 1600G. The glass melt wets the ceramic rod and long continuous glass fibers were easily hand drawn. The glass fibers were immediately coated with a protective polymer to maintain the mechanical strength. The viability of sulfur concrete as a construction material for extraterrestrial application is presented. The mechanical properties of the glass fiber reinforced sulfur concrete were investigated.
Toutanji, H.↗
Crystallization, Optical and Chemical Properties of Fluoride Glasses
Fluoride glasses have great promise as infrared optical components, especially fibers, because they are transparent to 8 micrometers and higher. In order to optimize properties, different glass compositions are needed. Some are hard to form in a container, and may possibly be formable in a containerless furnace. Understanding of crystallization with and without a container could lead to glasses with optimum properties. Chemical durability (attack by water) can limit or extend the applicability of fluoride glasses. Progress to date is given.
Doremus, R. H.↗
Quasi-containerless glass formation method and apparatus
Glass rods or fibers are prepared from a polycrystalline rod by heating a short section of the rod in a first furnace to form a molten zone of the rod, heating a second short section of the rod in a second furnace to form a second molten zone and gradually moving the furnaces apart from one another to form an elongated molten float zone, which is cooled in its midsection to produce a glass rod between the molten zones. In another embodiment a single moving furnace assembly and a precursor rod with compositional gradient sections, are used, and the moving furnace traverses the rod so that the molten portion is drawn out to a degree whereby a fiber of ultrapure glass is formed.
Naumann, Robert J.↗