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The characteristics of the space environment were reviewed. Potential applications of space processing are discussed and include metallurgical processing, and processing of semiconductor materials. The behavior of fluid in low gravity is described. The evolution of apparatus for materials processing in space was reviewed.
Currently there is considerable interest in developing in-situ materials processing plants for both the Moon and Mars. Two of the most important aspects of developing such a materials processing plant is the overall system design and the integration of the different technologies into a reliable, lightweight, and cost-effective unit. The concept of an autonomous materials processing plant that is capable of producing useful substances from lunar regolith was developed. In order for such a materials processing plant to be considered as a viable option, it must be totally self-contained, able to operate autonomously, cost effective, light weight, and fault tolerant. In order to assess the impact of different technologies on the overall systems design and integration, a one-half scale model was constructed that is capable of scooping up (or digging) lunar soil, transferring the soil to a solar furnace, heating the soil in the furnace to liberate the gasses, and transferring the spent soil to a 'tile' processing center. All aspects of the control system are handled by a 386 class PC via D/A, A/D, and DSP (Digital Signal Processor) control cards.
The development of high temperature containerless processing equipment and the design and evaluation of associated systems required for microgravity materials processing and property measurements are discussed. Efforts were directed towards the following task areas: design and development of a High Temperature Acoustic Levitator (HAL) for containerless processing and property measurements at high temperatures; testing of the HAL module to establish this technology for use as a positioning device for microgravity uses; construction and evaluation of a brassboard hot wall Acoustic Levitation Furnace; construction and evaluation of a noncontact temperature measurement (NCTM) system based on AGEMA thermal imaging camera; construction of a prototype Division of Amplitude Polarimetric Pyrometer for NCTM of levitated specimens; evaluation of and recommendations for techniques to control contamination in containerless materials processing chambers; and evaluation of techniques for heating specimens to high temperatures for containerless materials experimentation.
High temperature materials such as silicon carbide, a variety of nitrides, and ceramic matrix composites find use in aerospace, automotive, machine tool industries and in high speed civil transport applications. Chemical vapor deposition (CVD) is widely used in processing such structural materials. Variations of CVD include deposition on substrates, coating of fibers, inside cavities and on complex objects, and infiltration within preforms called chemical vapor infiltration (CVI). Our current knowledge of the process mechanisms, ability to optimize processes, and scale-up for large scale manufacturing is limited. In this regard, computational modeling of the processes is valuable since a validated model can be used as a design tool. The effort is similar to traditional chemically reacting flow modeling with emphasis on multicomponent diffusion, thermal diffusion, large sets of homogeneous reactions, and surface chemistry. In the case of CVI, models for pore infiltration are needed. In the present talk, examples of SiC nitride, and Boron deposition from the author's past work will be used to illustrate the utility of computational process modeling.
The spot heating of samples, suspended in an acoustic field, was investigated to determine if the technique could be used to process materials. A single axis resonance device operating in air at 25 C with an rms pressure maximum of 160 to 170 db was used in the experiments. The heat flow from a hot object suspended in a levitation node is dominated by the effects of the field, with the heat loss approximately 20 times larger than that due to natural convection. The acoustic forces which suspend the body at a node also serve to eject the heated air. The coupling between the locally heated region around the body and the acoustic field results in instabilities in both the pressure wave and force field. The investigations indicated the extreme difficulties in developing a materials processing device based on acoustic/spot heating for use in a terrestrial environment.
The Office of Commercial Programs (OCP), working in conjunction with NASA engineers at the Goddard Space Flight Center, is supporting research efforts in robot technology and microelectronics materials processing that will provide many spinoffs for science and industry. The Telerobotic Materials Processing Experiment (TRMPX) is a Shuttle-launched materials processing test payload using a Get Away Special can. The objectives of the project are to define, develop, and demonstrate an automated materials processing capability under realistic flight conditions. TRMPX will provide the capability to test the production processes that are dependent on microgravity. The processes proposed for testing include the annealing of amorphous silicon to increase grain size for more efficient solar cells, thin film deposition to demonstrate the potential of fabricating solar cells in orbit, and the annealing of radiation damaged solar cells.
This paper discusses results of our work on development of the Optical Waveguide (OW) Solar Energy System for Lunar Materials Processing. In the OW system as shown, solar radiation is collected by the concentrator which transfers the concentrated solar radiation to the OW transmission line consisting of low-loss optical fibers. The OW line transmits the solar radiation to the thermal reactor of the lunar materials processing plant. The feature of the OW system are: (1) Highly concentrated solar radiation (up to 104 suns) can be transmitted via flexible OW lines directly into the thermal reactor for materials processing: (2) Solar radiation intensity or spectra can be tailored to specific materials processing steps; (3) Provide solar energy to locations or inside of enclosures that would not otherwise have an access to solar energy; and (4) The system can be modularized and can be easily transported to and deployed at the lunar base.
Projects involved in the materials processing in space program are listed. The research task involved in each project and the space hardware required for projects in the physical and chemical sciences and in materials processing are summarized.
Some considerations regarding materials processing in space are covered from a commercial perspective. Key areas include power, proprietary data, operational requirements (including logistics), and also the center of gravity location, and control of that location with respect to materials processing payloads.
The processing of materials via laser irradiation is presented in a brief survey. Various techniques currently used in laser processing are outlined and the significance to the development of space qualified microinstrumentation are identified. In general the laser processing technique permits the transferring of patterns (i.e. lithography), machining (i.e. with nanometer precision), material deposition (e.g., metals, dielectrics), the removal of contaminants/debris/passivation layers and the ability to provide process control through spectroscopy.
This Technical Memorandum (TM) is a survey outline of materials processing experiments aboard Space Shuttle Mission STS-47: Spacelab J, a joint venture between NASA and the National Space Development Agency of Japan. The mission explored materials processing experiments including electronics and crystal growth materials, metals and alloys, glasses and ceramics, and fluids. Experiments covered include Growth of Silicone Spherical Crystals and Surface Oxidation, Growth Experiment of Narrow Band-Gap Semiconductor Lead-Tin-Tellurium Crystals in Space, Study on Solidification of Immiscible Alloys, Fabrication of Very-Low-Density, High-Stiffness Carbon Fiber/Aluminum Hybridized Composites, High Temperature Behavior of Glass, and Study of Bubble Behavior. The TM underscores the historical significance of these experiments in the context of materials processing in space.
An attempt is made to provide pertinent and readily usable information on the extraterrestrial processing of materials and manufacturing of components and elements of these planned large space systems from preprocessed lunar materials which are made available at a processing and manufacturing site in space. Required facilities, equipment, machinery, energy and manpower are defined.
The findings and recommendations of the Materials Processing and Space Manufacturing group of the space shuttle payload planning activity are presented. The effects of weightlessness on the levitation processes, mixture stability, and control over heat and mass transport in fluids are considered for investigation. The research and development projects include: (1) metallurgical processes, (2) electronic materials, (3) biological applications, and (4)nonmetallic materials and processes. Additional recommendations are provided concerning the allocation of payload space, acceptance of experiments for flight, flight qualification, and private use of the space shuttle.
The next millennium challenges us to produce innovative materials, processes, manufacturing, and environmental technologies that meet low-cost aerospace transportation needs while maintaining US leadership. The pursuit of advanced aerospace materials, manufacturing processes, and environmental technologies supports the development of safer, operational, next-generation, reusable, and expendable aeronautical and space vehicle systems. The Aerospace Materials, Processes, and Environmental Technology Conference (AMPET) provided a forum for manufacturing, environmental, materials, and processes engineers, scientists, and managers to describe, review, and critically assess advances in these key technology areas.
This task encompassed a wide range of activities related to materials processing in space. For example, all aspects of the space station's flight and ground based systems design were assessed for the Office of Advanced Concepts and Technology (OACT) Space Processing Division Office. Activities for that organization also included the consolidation of space processing payload requirements for the space station and the development of an OACT payload operations plan. Similar duties were performed for the MSFC Payload Project Office. The SPACECOM database was used to conduct preliminary design studies for microgravity payload carriers and to conduct assessments of materials processing technology. Concepts for the Advanced Protein Crystal Growth Facility (APCGF) were developed. Materials processing vent products were analyzed and a furnace facility filter concept was developed using those studies. A preliminary design for a space station aluminum payload rack was developed. Analysis was conducted to characterize the acceleration environment onboard the space shuttle. Equipment for two fluid experiment apparatus was designed and manufactured for the Space Science Laboratory. The Fluids and Materials Experiments (FAME) data base was expanded. Also, Mir payload integration, technology transfer, and spacelab-to-space station transition studies were conducted.
The development of low cost material processes is essential to the achievement of economical liquid rocket propulsion systems in the next century. This paper will present the results of the evaluation of some promising material processes including powder metallurgy, vacuum plasma spray, metal spray forming, and bulge forming. The physical and mechanical test results from the samples and subscale hardware fabricated from high strength copper alloys and superalloys will be discussed.
A report describes investigations of materials processing in low-gravity environment. Ultimately, research could lead to new commercially-applicable materials and processes and to an understanding of constraints imposed by gravity. NASA-supported work is carried out in 46 academic, industrial, and Government laboratories, and covers a number of areas. An overview is given of objective and current state of development for over 100 tasks.
A new method is described, including results, to measure, control, and follow containerless processing in ground based levitators. This technique enables instantaneous optical property measurements from a transient solid or liquid surface concurrent with true temperature measurement. This was used successfully as a diagnostic tool to follow processing of Al, Si, and Ti during electromagnetic levitation. Experiments on Al show the disappearance of the oxide (emittance 0.33) at ca. 1300 C leaving a liquid surface with an emittance of 0.06. Electromagnetic levitation of silicon shows a liquid with a constant emittance (0.2) but with a solid whose emittance decreases very rapidly with increasing temperature. Consequently, the processing of materials at high temperatures can be controlled quite well through the control of surface optical properties.