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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Silicon Foils Growth by Interface-controlled Crystallization

During interface controlled crystallization (ICC) the chance to accelerate the removal of crystallization heat is the basis for high pulling rates of about 100 mm/min. The forced heat flow from the extended crystallization front to a cooling ramp is controlled by a lubricating melt film which also influences the crystallization behavior by suppressing nucleation centers. The basic principles of this full casting technique are presented and the influences of process parameters on the morphology of prepared silicon foils are demonstrated. Three different types of crystalline structure were found in silicon foils grown to ICC technique: dendritic, coarse granular and monocrystalline with (111) 211 orientation. The criteria for their appearance of process variables are discussed.

Helmreich, D.↗
NASA NTRS1984

Process research of non-CZ silicon material

Advanced processing techniques for non-CZ silicon sheet material that might improve the cost effectiveness of photovoltaic module production were investigated. Specifically, the simultaneous diffusion of liquid boron and liquid phosphorus organometallic precursors into n-type dendritic silicon web was examined. The simultaneous junction formation method for solar cells was compared with the sequential junction formation method. The electrical resistivity of the n-n and p-n junctions was discussed. Further research activities for this program along with a program documentation schedule are given.

Campbell, R. B.↗
NASA NTRS1984

Flat-plate solar array project process development area, process research of non-CZ silicon material

The program is designed to investigate the fabrication of solar cells on N-type base material by a simultaneous diffusion of N-type and P-type dopants to form an P(+)NN(+) structure. The results of simultaneous diffusion experiments are being compared to cells fabricated using sequential diffusion of dopants into N-base material in the same resistivity range. The process used for the fabrication of the simultaneously diffused P(+)NN(+) cells follows the standard Westinghouse baseline sequence for P-base material except that the two diffusion processes (boron and phosphorus) are replaced by a single diffusion step. All experiments are carried out on N-type dendritic web grown in the Westinghouse pre-pilot facility. The resistivities vary from 0.5 (UC OMEGA)cm to 5 (UC OMEGA)cm. The dopant sources used for both the simultaneous and sequential diffusion experiments are commercial metallorganic solutions with phosphorus or boron components. After these liquids are applied to the web surface, they are baked to form a hard glass which acts as a diffusion source at elevated temperatures. In experiments performed thus far, cells produced in sequential diffusion tests have properties essentially equal to the baseline N(+)PP(+) cells. However, the simultaneous diffusions have produced cells with much lower IV characteristics mainly due to cross-doping of the sources at the diffusion temperature. This cross-doping is due to the high vapor pressure phosphorus (applied as a metallorganic to the back surface) diffusion through the SiO2 mask and then acting as a diffusant source for the front surface.

Campbell, R. B.↗
NASA NTRS1983

Process research of non-CZ silicon material

High risk, high payoff research areas associated with the Westinghouse process for producing photovoltaic modules using non- CZ sheet material were investigated. All work was performed using dendritic web silicon. The following tasks are discussed and associated technical results are given: (1) determining the technical feasibility of forming front and back junctions in non-CT silicon using dopant techniques; (2) determining the feasibility of forming a liquid applied diffusion mask to replace the more costly chemical vapor deposited SiO2 diffusion mask; (3) determining the feasibility of applying liquid anti-reflective solutions using meniscus coating equipment; (4) studying the production of uniform, high efficiency solar cells using ion implanation junction formation techniques; and (5) quantifying cost improvements associated with process improvements.

Source record↗
NASA NTRS1983

Progress research of non-Cz silicon material

The simultaneous diffusion of liquid boron and liquid phosphorus dopants into N-type dendritic silicon web for solar cells was investigated. It is planned that the diffusion parameters required to achieve the desired P(+)NN(+) cell structure be determined and the resultant cell properties be compared to cells produced in a sequential differential process. A cost analysis of the simultaneous junction formation process is proposed.

Campbell, R. B.↗
NASA NTRS1984

Bulk undercooling

Bulk undercooling methods and procedures will first be reviewed. Measurement of various parameters which are necessary to understand the solidification mechanism during and after recalescence will be discussed. During recalescence of levitated, glass-encased large droplets (5 to 8 mm diam) high speed temperature sensing devices coupled with a rapid response oscilloscope are now being used at MIT to measure local thermal behavior in hypoeutectic and eutectic binary Ni-Sn alloys. Dendrite tip velocities were measured by various investigators using thermal sensors or high speed cinematography. The confirmation of the validity of solidification models of bulk-undercooled melts is made difficult by the fineness of the final microstructure, the ultra-rapid evolution of the solidifying system which makes measurements very awkward, and the continuous modification of the microstructure which formed during recalescence because of precipitation, remelting and rapid coarsening.

Kattamis, T. Z.↗
NASA NTRS1984

Solidification study of some Ni- and Co-base alloys

An ongoing research program aims to characterize the solidification of several Ni- and Co-based commercial wrought type alloys. The techniques used and the data items sought are: (1) thermal analysis, liquidus, nonequilibrium solidus as a function of cooling rate, secondary reactions temperatures, incipient melting, progress of solidification as a function of temperature; (2) optical metallography, characteristic structures and secondary dendrite arm spacing as a function of cooling rate; (3) X-ray diffraction, identification of precipitates; and (4) SEM/EDAX, measure of microsegregation.

Jeanfils, C. L.↗
NASA NTRS1984

Microsegregation during directional solidification

During the directional solidification of alloys, solute inhomogeneities transverse to the growth direction arise due to morphological instabilities (leading to cellular or dendritic growth) and/or due to convection in the melt. In the absence of convection, the conditions for the onset of morphological instability are given by the linear stability analysis of Mullins and Sekerka. For ordinary solidification rates, the predictions of linear stability analysis are similar to the constitutional supercooling criterion. However, at very rapid solidification rates, linear stability analysis predicts a vast increase in stabilization in comparison to constitutional supercooling.

Coriell, S. R.↗
NASA NTRS1984

Solidification structures grown under induced flow and continuous casting of steel

The use of induced flow as a means to control solidification structures in strand cast steel is investigated. The quality problems in strand cast steel stemming from columnar growth can be partially controlled, by Electro Magnetic Stirring (EMS). Induced flow changes the normal morphology of dendrites. Solids grown under intense stirring conditions show both negative and positive segregation which is considered unacceptable by some steel producers. The inclusion size and population is strongly affected by induced flow (EMS). Laboratory and industrial data show substantial reduction in inclusion size and content, but the overall effect of flow on inclusions is affected by the particular type of flow patterns utilized in each case. Productivity and quality are raised substantially in steel strand casting by utilizing EMS.

Tsavaras, A. A.↗
NASA NTRS1984

Nature of gamma-prime precipitates in rheocast IN-100 alloy

The microstructures of commercial VIM-cast and rheocast (Apelian and Cheng, 1983) IN-100 superalloy are investigated optically and by two-stage replica TEM, with an emphasis on the nature of the gamma-prime (GP) precipitates. Photomicrographs at magnifications of 39, 390, 2145, and 6630 are presented and discussed. VIM-cast IN-100 has dendritic structure, 10-20-micron primary GP particles, and uniformly distributed cuboid GP precipitates of a uniform size (about 0.5 micron). Rheocast IN-100 (stirred 20 min at 350 rpm, 1291 C, and 0.0006 torr) has a nondendritic structure, 20-100-micron primary GP particles, and a smaller volume fraction of cuboid GP precipitates with a bimodal (either 1-1.5 microns or less than 0.5 micron) size distribution. Such distribution should increase fatigue-crack-nucleation resistance.

Surappa, M. K.↗
NASA NTRS1984

Boundary-layer model of pattern formation in solidification

A model of pattern formation in crystal growth is proposed, and its analytic properties are investigated. The principal dynamical variables in this model are the curvature of the solidification front and the thickness (or heat content) of a thermal boundary layer, both taken to be functions of position along the interface. This model is mathematically much more tractable than the realistic, fully nonlocal version of the free-boundary problem, and still recaptures many of the features that seem essential for studying dendritic behavior, for example. Preliminary numerical solutions produce snowflakelike patterns similar to those seen in nature.

Ben-Jacob, E.↗
NASA NTRS1984

Pattern selection in solidification

Directional solidification of alloys produces a wide variety of cellular or lamellar structures which, depending upon growth conditions, may be reproducibly regular or may behave chaotically. It is not well understood how these patterns are selected and controlled or even whether there ever exist sharp selection mechanisms. A related phenomenon is the spatial propagation of a pattern into a system which has been caused to become unstable against pattern-forming deformations. This phenomenon has some features in common with the propagation of sidebranching modes in dendritic solidification. In a class of one-dimensional models, the nonlinear system can be shown to select the propagating mode in which the leading edge of the pattern is just marginally stable. This stability principle, when applicable, predicts both the speed of propagation and the geometrical characteristics of the pattern which forms behind the moving front. A boundary-layer model for fully two or three dimensional solidification problems appears to exhibit similar mathematical behavior.

Langer, J. S.↗
NASA NTRS1984

Solidification of highly undercooled Sn-Pb alloy droplets

Experimental work on undercooling and structure of tin-lead droplets emulsified in oil is described. The droplets, predominantly in the size range of 10 to 20 microns, were cooled at rates (just before nucleation) ranging from about 0.1 to 1 million K/s. The higher cooling rates were obtained by a newly developed technique of quenching the emulsified droplets in a cold liquid. Measured undercoolings (at the lower cooling rates) ranged up to about 100 K. Structures obtained depend strongly on undercooling, cooling rate before and after nucleation, and alloy composition. Droplets containing up to 5 wt pct Pb were apparently single phase when undercooled and rapidly quenched. Droplets in the composition range of about 25-90 wt pct Pb solidified dendritically, even at the most rapid quench rates employed, apparently because these alloys undercooled only slightly before nucleation of the primary phase.

Chu, M. G.↗
NASA NTRS1984

Solidification of undercooled metals

The present investigation is concerned with the subject of undercooling (i.e., supercooling) in the case of metal alloys, taking into account the effects of undercooling on microstructure and microsegregation in alloys which solidify in a crystalline manner. Techniques for obtaining a large degree of undercooling are discussed. These techniques make it possible to eliminate heterogeneous nucleants from the melt and to remove container nucleation effects. The nucleation behavior of small metal droplets is considered along with the formation of a dispersion of fine droplets in a suitable inert medium, the mixing of fine metal powders with glass powder, and the levitation melting technique. Attention is given to solidification with rapid interface velocity, aspects of dendritic morphology, and thermal measurements during solidification of undercooled droplets.

Flemings, M. C.↗
NASA NTRS1985

Prototype Furnace for Automatic Production of Silicon Ribbon

Single-crystal material grown under precise control. New furnace permits sustained growth of single-crystal silicon ribbon by dendritic-web growth process. Furnace brings together mechanisms necessary for continuous automatic operation.

Duncan, C. S.↗
NASA NTRS1985

Adjustable Lid Aids Silicon-Ribbon Growth

Closely-spaced crucible cover speeds up solidification. Growth rate of dendritic-web silicon ribbon from molten silicon increased by controlling distance between crucible susceptor lid and liquid/solid interface. Lid held in relatively high position when crucible newly filled with chunks of polycrystalline silicon. As silicon melts and forms pool of liquid at lower level, lid gradually lowered.

Mchugh, J. P.↗
NASA NTRS1984

Results of the technical exchange agreement between NASA and DuPont on the containerless drop tube solidification of NiAl3

The final results of the Drop Tube Solidification of NiAl3 are presented. Problems associated with the utilization of a dripper furnace in the drop tube are discussed and the modification of experimental procedures required to achieve results are described. Sample microstructures of drop tube samples are compared with other samples. The dendrite arm spacings of drop tube samples are correlated with the rapid cooling rates.

Ethridge, E. C.↗
NASA NTRS1984

Containerless drop tube solidification and grain refinement of NiAl3

The possibility of undercooling Ni-Al alloys below the liquidus in order to produce a single phase peritectic structure by containerless drop tube solidification was studied. Containerless process is a technique for both high purity contamination free studies as well as for investigating the undercooling and rapid solidification of alloys by suppression of heterogeneous nucleation on container walls. In order to achieve large undercoolings one must avoid heterogeneous nucleation of crystallization. It was shown that the Marshall Space Flight Center drop tubes ae unique facilities for containerless solidification experiments and large undercoolings are possible with some alloys. The original goal of undercooling the liquid metal well below the liquidus to the peritectic temperature during containerless free to form primarily NiAl3 was achieved. The microstructures were interesting from another point of view. The microstructure from small diameter samples is greatly refined. Small dendrite arm spacings such as these could greatly facilitate the annealing and solid state transformation of the alloy to nearly 10% NiAl3 by reducing the distance over which diffusion needs to occur. This could minimize annealing time and might make it economically feasible to produce NiAl3 alloy.

Ethridge, E. C.↗