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At least 883 records · Page 49

Cost Models for MMC Manufacturing Processes

The quality cost modeling (QCM) tool is intended to be a relatively simple-to-use device for obtaining a first-order assessment of the quality-cost relationship for a given process-material combination. The QCM curve is a plot of cost versus quality (an index indicating microstructural quality), which is unique for a given process-material combination. The QCM curve indicates the tradeoff between cost and performance, thus enabling one to evaluate affordability. Additionally, the effect of changes in process design, raw materials, and process conditions on the cost-quality relationship can be evaluated. Such results might indicate the most efficient means to obtain improved quality at reduced cost by process design refinements, the implementation of sensors and models for closed loop process control, or improvement in the properties of raw materials being fed into the process. QCM also allows alternative processes for producing the same or similar material to be compared in terms of their potential for producing competitively priced, high quality material. Aside from demonstrating the usefulness of the QCM concept, this is one of the main foci of the present research program, namely to compare processes for making continuous fiber reinforced, metal matrix composites (MMC's). Two processes, low pressure plasma spray deposition and tape casting are considered for QCM development. This document consists of a detailed look at the design of the QCM approach, followed by discussion of the application of QCM to each of the selected MMC manufacturing processes along with results, comparison of processes, and finally, a summary of findings and recommendations.

Elzey, Dana M.↗

p-n Junction Diodes Fabricated on Si-Si/Ge Heteroepitaxial Films

A set of photolithographic masks was designed for the fabrication of diodes in the Si-Si/Ge material system. Fabrication was performed on samples obtained from two different wafers: (1) a complete HBT structure with an n (Si emitter), p (Si/Ge base), and an n/n+ (Si collector/sub-collector) deposited epitaxially (MBE) on a high resistivity p-Si substrate, (2) an HBT structure where epitaxial growth was terminated after the p-type base (Si/Ge) layer deposition. Two different process runs were attempted for the fabrication of Si-Si/Ge (n-p) and Si/Ge-Si (p-n) junction diodes formed between the emitter-base and base-collector layers, respectively, of the Si-Si/Ge-Si HBT structure. One of the processes employed a plasma etching step to expose the p-layer in the structure (1) and to expose the e-layer in structure (2). The Contact metallization used for these diodes was a Cu-based metallization scheme that was developed during the first year of the grant. The plasma-etched base-collector diodes on structure (2) exhibited well-behaved diode-like characteristics. However, the plasma-etched emitter-base diodes demonstrated back-to-back diode characteristics. These back-to back characteristics were probably due to complete etching of the base-layer, yielding a p-n-p diode. The deep implantation process yielded rectifying diodes with asymmetric forward and reverse characteristics. The ideality factor of these diodes were between 1.6 -2.1, indicating that the quality of the MBE grown epitaxial films was not sufficiently high, and also incomplete annealing of the implantation damage. Further study will be conducted on CVD grown films, which are expected to have higher epitaxial quality.

Das, K.↗

Plasma assisted distributed chemical production

The present development is a process to produce commodity chemicals such as methanol and syngas using an integrated plasma catalysis technology. The method comprises providing a fixed or fluidized bed reactor having a microwave plasma flame and a catalyst bed with a catalyst, wherein the catalyst is an alloyed bimetallic nanowire. In the process, the plasma flame fluidizes the catalyst thereby producing a more effective catalyst than the non-fluidized catalyst. It is anticipated that the reactor can have a throughput capacity of up to 30 Lpm/kW and can be effective for the conversion of CO 2 , CH 4 , air, water, and combinations thereof, through reactions such as pure CO 2 splitting, reverse water gas shift (RWGS) for CO production, methanol synthesis, and plasma reforming of methane, thereby making a system that would be attractive for small GTL units.

Sunkara, Mahendra↗

Ignitor plug erosion and arc initiation processes in a one-millipound pulsed plasma thruster

The results are presented of a one-millipound pulsed plasma ignition system study. The preliminary data indicate that inductively coupling the ignition plug cathode to the thruster cathode is more beneficial to ignitor plug longevity than resistive coupling. These benefits arise from the ability of the coupling conductor to control the build-up of a carbonaceous deposit on the plug face. The deposit build-up is a strong function of the peak coupling current experienced during thruster operation. The relationship between the ignitor plug discharge and thruster discharge is shown to be very complex with equivalent circuit elements which are dynamic in nature. A preliminary representation of this equivalent circuit is developed.

Aston, G.↗

Physical processes in photon-starved nonthermal pair plasmas

Compton spectra produced by relativistic, unmagnetized, nonthermal electron-positron pairs injected into 'photon-starved' plasmas, where the luminosity in soft photons is much less than the power in the nonthermal pair injection, are studied. The overall form of the spectra consists of a rising spectrum at low energies, a single or double peak in the 0.1-1 MeV energy range, a cutoff above the peak, and a gamma-ray tail with a varying slope depending on the plasma parameters. The low-energy power law is mostly due to the primary soft photons being repeatedly upscattered by the hot thermal electrons. Comparisons are made with observations of compact objects.

Zdziarski, Andrzej A.↗

Dust-gas Interactions in Dusty X-ray Emitting Plasmas

Dusty shocked plasmas cool primarily by infrared emission from dust that is collisionally heated by the ambient hot gas. The infrared emission provides therefore an excellent diagnostic of the conditions (density and temperature) of the shocked gas. In this review I will discuss the physical processes in these plasmas, with a particular emphasis on recent infrared observations of the interaction between the blast wave of SN1987a and its equatorial ring.

Dwek, Eli↗

Numerical benchmark of transient pressure-driven metallic melt flows

Fluid dynamics simulations of melting and crater formation at the surface of a copper cathode exposed to high plasma heat fluxes and pressure gradients are presented. The predicted deformations of the free surface and the temperature evolution inside the metal are benchmarked against previously published simulations. Despite the physical model being entirely hydrodynamic and ignoring a variety of plasma–surface interaction processes, the results are also shown to be remarkably consistent with the predictions of more advanced models, as well as experimental data. This provides a sound basis for future applications of similar models to studies of transient surface melting and droplet ejection from metallic plasma-facing components after disruptions.

36 MATERIALS SCIENCE↗

The Role of Water Vapor and Dissociative Recombination Processes in Solar Array Arc Initiation

Experimental plasma arc investigations involving the onset of arc initiation for a negatively biased solar array immersed in low-density plasma have been performed. Previous studies into the arc initiation process have shown that the most probable arcing sites tend to occur at the triple junction involving the conductor, dielectric and plasma. More recently our own experiments have led us to believe that water vapor is the main causal factor behind the arc initiation process. Assuming the main component of the expelled plasma cloud by weight is water, the fastest process available is dissociative recombination (H2O(+) + e(-) (goes to) H* + OH*). A model that agrees with the observed dependency of arc current pulse width on the square root of capacitance is presented. A 400 MHz digital storage scope and current probe was used to detect arcs at the triple junction of a solar array. Simultaneous measurements of the arc trigger pulse, the gate pulse, the arc current and the arc voltage were then obtained. Finally, a large number of measurements of individual arc spectra were obtained in very short time intervals, ranging from 10 to 30 microseconds, using a 1/4 a spectrometer coupled with a gated intensified CCD. The spectrometer was systematically tuned to obtain optical arc spectra over the entire wavelength range of 260 to 680 nanometers. All relevant atomic lines and molecular bands were then identified.

Galofar, J.↗

Mechanisms of graphite ablation by sub-millisecond ytterbium fiber laser pulses

Graphite is a key material in a variety of cross-cutting applications in energy conversion, energy storage, and nuclear energy. Recently, temporally modulated continuous wave lasers have been shown to produce well-defined ablation features in graphite at relatively high processing speeds. In this work, we analyze in detail the laser ablation dynamics of single-pulse ablation in the sub-millisecond time regime to elucidate the origins of the resulting well-defined ablation craters using a combination of time-resolved emission imaging, diffuse reflection/scattering imaging, and optical emission spectroscopy. These multimodal in situ diagnostics revealed three main contributors to achieve well-defined ablation features: (1) rapid ejection of particles with ~100 m/s speed, (2) ablation of the graphite in the gaseous form, and (3) absence of bulk liquid motion, which is typically observed in laser processing of metals. Plasma plume formation was sustained throughout the duration of the laser pulse (500 μs). Here, this work provides insights into the complex physical and chemical mechanisms of sub-millisecond laser–matter interactions, which are critical for parameter space optimization and tailoring of laser machining and drilling processes.

42 ENGINEERING↗

Fundamental Studies in Basic Plasma Science: Experimental Investigations of Alfven Wave Damping Processes Relevant to the Solar Corona (Final Report)

Motivated by recent observations suggesting that the solar corona is heated by Alfvén wave damping at unexpectedly low heights, we performed experiments to study the basic plasma physics of Alfvén wave dissipation. Proposed coronal damping mechanisms rely on inhomogeneities in the plasma, but these theories have not been systematically studied in the laboratory. We performed experiments using the Large Plasma Device (LAPD) to test these theories.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

HRTEM Imaging and Mechanistic Insights Into Carbon Nanotube Nucleation and Growth on Fe Nanocatalysts in a Thermal Plasma

Thermal plasma decomposition of natural gas is a scalable pathway for the production of hydrogen alongside high-value carbon nanotubes (CNTs). Metals evaporate from an electrode and condense to form seed nanoparticles that nucleate and grow CNTs. However, the lack of mechanistic understanding of the CNT nucleation and growth processes in thermal plasma makes control over CNT diameter, chirality, length, and yield difficult. We debundled and separated CNTs from soots produced using iron (Fe) nanocatalysts, and distributed them on monolayer graphene for high-resolution transmission electron microscopy (HRTEM) imaging to gain mechanistic insights. Full graphene encapsulation was found for relatively small Fe nanoparticles that were molten at high temperatures. Zigzag single-wall or double-wall CNTs (SWCNTs or DWCNTs) appeared to have grown out directly from the graphene covering on the conical or cylindrical bodies of small molten Fe nanodroplets with high curvature. Also, SWCNTs likely grew out from H- or O-atom etched single-wall carbon nanocones observed on conical Fe nanoparticles. A SWCNT/DWCNT could also be generated from the cracked opening of the graphene covering on a face-centered cubic (FCC) Fe nanoparticle. A simple, plausible pathway is proposed for the growth of an open, H-passivated, zigzag SWCNT involving reaction of CH 2 and CH radicals at high temperatures.

Fe nanocatalysts↗

In situ CF3 Detection in Low Pressure Inductive Discharges by Fourier Transform Infrared Spectroscopy

The detection of CF(x) (x=1-3) radicals in low pressure discharges using source gases such as CF4 and CHF3 is of importance to the understanding of their chemical structure and relevance in plasma based etching processes. These radicals are known to contribute to the formation of fluorocarbon polymer films, which affect the selectivity and anisotropy of etching. In this study, we present preliminary results of the quantitative measurement of trifluoromethyl radicals, CF3, in low pressure discharges. The discharge studied here is an inductively (transformer) coupled plasma (ICP) source in the GEC reference cell, operating on pure CF4 at pressures ranging from 10 - 100 mTorr, This plasma source generates higher electron number densities at lower operating pressures than obtainable with the parallel-plate capacitively coupled version of the GEC reference cell. Also, this expanded operating regime is more relevant to new generations of industrial plasma reactors being used by the microelectronics industry. Fourier transform infrared (FTIR) spectroscopy is employed to observe the absorption band of CF3 radicals in the electronic ground state X2Al in the region of 1233-1270/cm. The spectrometer is equipped with a high sensitivity HgCdTe (MCT) detector and has a fixed resolution of 0.125/cm. The CF3 concentrations are measured for a range of operating pressures and discharge power levels.

Kim, J. S.↗

Measurements of energy distribution and wall temperature in flowing hydrogen microwave plasma systems

An electrothermal propulsion concept utilizing a microwave plasma system as the mechanism to convert electromagnetic energy into translational energy of the flowing gas is being investigated. A calorimetric experimental system has been designed and built enclosing the microwave plasma system to accurately determine the net energy transferred to the flowing gas. For a flow rate of 8900 micromoles/sec, a pressure of 7.4 torr, and an absorbed power level of 80 W, an energy transfer efficiency of 50 percent has been measured. A heat transfer model that characterizes the energy transfer processes in the plasma is developed. A wall temperature for the plasma system is calculated.

Chapman, R.↗

Plasma contacting - An enabling technology

An experimental study of plasma contacting with an emphasis on the electron collection mode of this process is described. Results illustrating variations in plasma property profiles and potential differences that develop at hollow cathode plasma contactors are presented. A model of the electron collection plasma contacting process that is consistent with experimentally measured results is reviewed. The shortcomings of laboratory results as direct predictors of contactor performance in space and their usefulness in validating numerical models of the contacting process, that can be used to predict such performance, are discussed.

Williams, John D.↗

Energetic Electrons Accelerated and Trapped in a Magnetic Bottle above a Solar Flare Arcade

Where and how flares efficiently accelerate charged particles remains an unresolved question. Recent studies revealed that a “magnetic bottle” structure, which forms near the bottom of a large-scale reconnection current sheet above the flare arcade, is an excellent candidate for confining and accelerating charged particles. However, further understanding its role requires linking the various observational signatures to the underlying coupled plasma and particle processes. Here we present the first study combining multiwavelength observations with data-informed macroscopic magnetohydrodynamics and particle modeling in a realistic eruptive flare geometry. The presence of an above-the-loop-top magnetic bottle structure is strongly supported by the observations, which feature not only a local minimum of magnetic field strength but also abruptly slowing plasma downflows. It also coincides with a compact above-the-loop-top hard X-ray source and an extended microwave source that bestrides the flare arcade. Spatially resolved spectral analysis suggests that nonthermal electrons are highly concentrated in this region. Our model returns synthetic emission signatures that are well matched to the observations. The results suggest that the energetic electrons are strongly trapped in the magnetic bottle region due to turbulence, with only a small fraction managing to escape. The electrons are primarily accelerated by plasma compression and facilitated by a fast-mode termination shock via the Fermi mechanism. Our results provide concrete support for the magnetic bottle as the primary electron acceleration site in eruptive solar flares. They also offer new insights into understanding the previously reported small population of flare-accelerated electrons entering interplanetary space.

79 ASTRONOMY AND ASTROPHYSICS↗

On the expansion of ionospheric plasma into the near-wake of the Space Shuttle Orbiter

During the Spacelab 2 mission, while the Plasma Diagnostics Package was attached to the Remote Manipulator System, differential ion vector measurements were obtained in the near wake at a distance of 4-5 Shuttle radii. The Orbiter's wake was found to fill in at a much faster rate than can be explained by simple thermal motion. The measurements strongly suggest that filling of the Orbiter's wake is produced by the process of 'collisionless plasma expansion into a vacuum' and that, for oblique angles of the magnetic field and velocity vectors, the near wake plasma depletion a few radii downstream is not sensitive to the body scale size.

Stone, N. H.↗

EUV spectroscopic plasma diagnostics for the solar wind acceleration region

Possibilities are considered for probing physical conditions in the solar corona with strong EUV resonance lines from ions such as N V, O VI, Ne VIII, Mg X, and Si XII. Through measurements of the intensities and profiles of EUV spectral lines with coronagraphic instrumentation employing normal incidence reflecting optics, it is possible to acquire information on electron, proton, and ion temperatures and velocity distributions; electron, H I, and ion densities; mass flow and nonthermal velocities; and chemical abundances. This information will provide critical empirical constraints on physical processes responsible for plasma heating, solar wind acceleration, and transport of mass, momentum, and energy in the solar corona, as well as providing constraints on theoretical models for solar and stellar coronae and mass loss.

Kohl, J. L.↗