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At least 685 records · Page 38

Sandia's Research in Support of COVID-19 Pandemic Response: Materials Science

Sandia Materials Science Investment Area contributed to the SARS-CoV-2 virus and COVID-19 disease which represent the most significant pandemic threat in over 100 years. We completed a series of 7, short duration projects to provide innovative materials science research and development in analytical techniques to aid the neutralization of COVID-19 on multiple surfaces, approaches to rapidly decontaminate personal protective equipment, and pareto assessment of construction materials for manufacturing personal protective equipment. The developed capabilities and processes through this research can help US medical personnel, government installations and assets, first responders, state and local governments, and multiple federal agencies address the COVID-19 Pandemic.

36 MATERIALS SCIENCE↗

Neutrons and Complementary Techniques for Quantum Materials

The virtual workshop “Neutrons and Complementary Techniques for Quantum Materials” was held September 6-8, 2022. As the investigation of quantum materials progresses, researchers can no longer deal with the bulk properties and surface states separately. Many open questions require the combination of complementary methods sensitive to different degrees of freedom to provide a more comprehensive view. This workshop intends to create a bridge for the science community focusing on different techniques to educate each other so we will gain a better understanding of the strength, weakness/limits, the most recent new developments, and future directions for each technique. Through this workshop we intended to raise the awareness of developments in techniques complimentary to neutron scattering, thereby maximizing the impact of our work and strengthening collaborations across experimental techniques in the research of quantum materials.

36 MATERIALS SCIENCE↗

Research study of materials processing in space Experiment M512

Ground based studies of two proposed experiments which were to be conducted aboard the Skylab Laboratory are reported; metals melting experiment, and sphere forming experiment. These studies were conducted with the objectives of clarifying the effects of gravity and optimizing the experiments within the constraints of existing hardware. All process phenomena were considered, with particular attention given to adhesion-cohesion studies with emphasis on the fluid dynamics of the molten metal. Detailed thermal histories were generated for three-dimensional specimen geometry including radiation, conduction and vaporization losses with allowances for variable properties. In addition quantitative techniques were used to establish the gravitational level (magnitude and direction) for KC-135 aircraft flights and the actual Skylab mission for both experiments.

Brashears, M. R.↗

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.↗

Research study on materials processing in space, M566 experiment

Specimens of the aluminum-33 wt% copper eutectic partially melted and resolidified in the low effective gravity of the orbiting Skylab were examined and characterized with respect to microstructural defects and thermal conductivity values. The results obtained were compared with similar evaluations of ground-based simulation melt-resolidification experiments and as-prepared unidirectionally solidified specimens. Thermal conductivity data and electrical resistivity data at temperatures from 25 C to 400 C did not show significant differences between ground and space processed specimens. A methology of evaluating the defects in the Al-Al2Cu structure was implemented. A specimen from Skylab 3 showed signs of instability in growth and several grains were found in the ingot. The specimen from Skylab 4 did not show such marked instability in growth and was found to contain fewer defects than the ground-processed specimens. This agrees with data from Georgia Institute of Technology which showed that there were fewer defects in both their Skylab 3 and 4 specimens than in ground processed specimens.

Douglas, F. C.↗

Research study on materials processing in space, experiment M512

Gallium arsenide, a commercially valuable semiconductor, has been prepared from the melt (M.P. 1237C), by vapor growth, and by growth from metallic solutions. It has been established that growth from metallic solution can produce material with high, and perhaps with the highest possible, chemical homogeneity and crystalline perfection. Growth of GaAs from metallic solution can be performed at relatively low temperatures (about 600C) and is relatively insensitive to temperature fluctuations. However, this type of crystal growth is subject to the decided disadvantage that density induced convection currents may produce variations in rates of growth at a growing surface. This problem would be minimized under reduced gravity conditions.

Rubenstein, M.↗

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.↗

Research study on materials processing in space experiment number M512

Conclusions of the team of specialists can be generalized as: (1) Brazing and welding of metal structures in an orbital near zero gravity condition are quite feasible. (2) Design of joints for fabrication in zero gravity will place less emphasis on the tolerances and proximity of the adjacent structures than on the quantity of liquid metal available. (3) Brazing of metallic joints has many advantages over electron beam welding for practical reasons: simplicity, launch weight, development costs, joint design tolerances, remotization, etc. (4) No evidence of different physical or mechanical properties of liquid metals in zero gravity was observed. However, many differences in liquid behavior were observed. Many of these effects have been called adhesion-cohesion phenomena.

Tobin, J. M.↗

Research study on materials processing in space experiment number M512

Adhesion of the melted metals to the adjacent solid metals, and cohesion of the liquid metal to itself appeared to be equally as strong in zero gravity as on earth. Similar cut edge bead periodicity in cut thin plate, and similar periodic chevron patterns in full penetration welds were seen. The most significant practical result is that the design of braze joints for near zero gravity can be very tolerant of dimensional gaps in the joint. This conclusion is based on a comparison of narrow, wide and variable gap widths. Brazing is very practical as a joining or repairing technique for metal structures at zero gravity. The operation of the hardware developed to locate successive small (0.6 cm) diameter cylinders in the focus of the battery powered EB unit, melt the various metal specimens and deploy some liquid metal drops to drift in space, was generally successful. However, the sphericity and surface roughness were far from those of ball bearings.

Tobin, J. M.↗

Flat-plate collector research area: Silicon material task

Silane decomposition in a fluidized-bed reactor (FBR) process development unit (PDU) to make semiconductor-grade Si is reviewed. The PDU was modified by installation of a new heating system to provide the required temperature profile and better control, and testing was resumed. A process for making trichlorosilane by the hydrochlorination of metallurgical-grade Si and silicon tetrachloride is reported. Fabrication and installation of the test system employing a new 2-in.-dia reactor was completed. A process that converts trichlorosilane to dichlorosilane (DCS), which is reduced by hydrogen to make Si by a chemical vapor deposition step in a Siemens-type reactor is described. Testing of the DCS PDU integraled with Si deposition reactors continued. Experiments in a 2-in.-dia reactor to define the operating window and to investigate the Si deposition kinetics were completed.

Lutwack, R.↗

Fatigue and fracture research in composite materials

The fatigue, fracture, and impact behavior of composite materials are investigated. Bolted and bonded joints are included. The solutions developed are generic in scope and are useful for a wide variety of structural applications. The analytical tools developed are used to demonstrate the damage tolerance, impact resistance, and useful fatigue life of structural composite components. Standard tests for screening improvements in materials and constituents are developed.

T. Kevin O'Brien↗

Safety research of insulating materials of cable for nuclear power generating station

The polymers PE, EPR, PVC, Neoprene, CSP, CLPE, EP and other similar substances are frequently used as insulation and protective covering for cables used in nuclear power generating stations. In order to test these materials for flame retardation, environmental resistance, and cable specifications, they were given the cable normal test, flame test, chemical tests, and subjected to design analysis and loss of coolant accident tests. Material was collected on spark tests and actual experience standards were established through these contributions and technology was accumulated.

Lee, C. K.↗

NDE of ceramics and ceramic composites

Although nondestructive evaluation (NDE) techniques for ceramics are fairly well developed, they are difficult to apply in many cases for high probability detection of the minute flaws that can cause failure in monolithic ceramics. Conventional NDE techniques are available for monolithic and fiber reinforced ceramic matrix composites, but more exact quantitative techniques needed are still being investigated and developed. Needs range from flaw detection to below 100 micron levels in monolithic ceramics to global imaging of fiber architecture and matrix densification anomalies in ceramic composites. NDE techniques that will ultimately be applicable to production and quality control of ceramic structures are still emerging from the lab. Needs are different depending on the processing stage, fabrication method, and nature of the finished product. NDE techniques are being developed in concert with materials processing research where they can provide feedback information to processing development and quality improvement. NDE techniques also serve as research tools for materials characterization and for understanding failure processes, e.g., during thermomechanical testing.

Vary, Alex↗