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High-risk, high-payoff improvements to a baseline process sequence of simultaneous junction formation of silicon solar cells are discussed. The feasibility of simultaneously forming front and back junctions of solar cells using liquid dopants on dendritic web silicon was studied. Simultaneous diffusion was compared to sequential diffusion. A belt furnace for the diffusion process was tested.
Dynamic crystallization experiments in which heterogeneous nucleation is an important variable have been completed on four melts of chondrule composition. Compositions were chosen to best represent chondrules with porphyritic pyroxene and radial pyroxene textures. Experimental results show that heterogeneous nucleation is essential for the formation of porphyritic textures. Without preexisting nuclei, too much supercooling is established before crystallization is initiated and the textures are more likely to be dendritic or radial. In the near total absence of nuclei, radial textures can form at cooling rates as slow as 5 C/hr in this study. By varying the heterogeneous nucleation conditions and having a melt in which the appropriate phases are stable or metastable, analogs to most of the recognized chondrule textures can be produced in a single melt composition.
A revolutionary way to produce a mirror and mirror assembly is to cast the entire part at once from a metal alloy that combines all of the desired features into the final part: optical smoothness, curvature, flexures, tabs, isogrids, low CTE, and toughness. In this work, it has been demonstrated that castable mirrors are possible using bulk metallic glasses (BMGs, also called amorphous metals) and BMG matrix composites (BMGMCs). These novel alloys have all of the desired mechanical and thermal properties to fabricate an entire mirror assembly without machining, bonding, brazing, welding, or epoxy. BMGs are multi-component metal alloys that have been cooled in such a manner as to avoid crystallization leading to an amorphous (non-crystalline) microstructure. This lack of crystal structure and the fact that these alloys are glasses, leads to a wide assortment of mechanical and thermal properties that are unlike those observed in crystalline metals. Among these are high yield strength, carbide-like hardness, low melting temperatures (making them castable like aluminum), a thermoplastic processing region (for improving smoothness), low stiffness, high strength-to-weight ratios, relatively low CTE, density similar to titanium alloys, high elasticity and ultra-smooth cast parts (as low as 0.2-nm surface roughness has been demonstrated in cast BMGs). BMGMCs are composite alloys that consist of a BMG matrix with crystalline dendrites embedded throughout. BMGMCs are used to overcome the typically brittle failure observed in monolithic BMGs by adding a soft phase that arrests the formation of cracks in the BMG matrix. In some cases, BMGMCs offer superior castability, toughness, and fatigue resistance, if not as good a surface finish as BMGs. This work has demonstrated that BMGs and BMGMCs can be cast into prototype mirrors and mirror assemblies without difficulty.
Liquid diffusion masks and liquid applied dopants to replace the CVD Silox masking and gaseous diffusion operations specified for forming junctions in the Westinghouse baseline process sequence for producing solar cells from dendritic web silicon were investigated.
In-situ identification of sulfates at the martian surface by the Mars Exploration Rovers and the Mars Science Laboratory have included calcium sulfates with various states of hydration (gypsum, bassanite, anhydrite), iron sulfates of likely fumarolic origin, massive deposits of iron hydroxysulfates indicative of an acidic history, and minor occurrences of magnesium sulfates. Recent measurements by the Opportunity and Curiosity Alpha Particle X-ray Spectrometers (APXS) have indicated the presence of Ni-substituted Mg-sulfates at the Meridiani Planum and Gale Crater landing sites. The Opportunity rover has traversed nearly 43 km and is currently exploring the impact breccias of the rim of Endeavour crater, near a location where signatures of aqueous alteration have been established from orbit. APXS analyses of subsurface materials excavated by a rover wheel show clear evidence for a Mg(Ni)-sulfate with Mg:Ni (is) approximately 100:1 (molar). On the other side of the planet, Curiosity is continuing its climb up Mount Sharp after driving (is) approximately 13 km since landing. Over the last 4 km of the traverse, there have been multiple chemical analyses of erosionally-resistant nodules and dendritic features in a finely laminated mudstone unit which also indicate Mg(Ni)-sulfate (Mg:Ni (is) approximately 30:1, molar). The geologic settings for the Endeavour rim and the Mount Sharp mudstones are clearly different, but similar formation conditions for these sulfates may be possible. Ni(2+) readily substitutes for Mg(2+) in a variety of geochemical processes due to their comparable ionic radii. The availability of soluble Ni at the time of Mg-sulfate precipitation suggests acidic solutions. The fluids responsible for alteration in the Endeavour rim and for the formation of nodules in Gale mudstones may have had similar chemical characteristics at the time the Mg-sulfates were formed.
Cylindrical Al-7 wt% Silicon, Al-19 wt% Copper and Lead-6 wt% Antimony alloy samples were directionally solidified (DS) with liquid above, solid below, and gravity pointing down, in graphite crucibles having an abrupt cross-sectional increase. These alloys have similar solidification shrinkage but are expected to have different degrees of thermosolutal convection during solidification. Microstructures in the DS samples in the vicinity of the section change have been studied in order to examine the effect of convection associated with the combined influence of thermosolutal effects and solidification shrinkage. Extensive radial and axial macrosegregation associated with cross-section change is observed. It also appears that steepling and local primary alpha-phase remelting resulting from convection are responsible for stray grain formation at the reentrant corners. Preliminary results from a numerical model, which includes solidification shrinkage and thermosolutal convection in the mushy zone, indicate that these regions are prone to solutal remelting of dendrites.
Since significantly different solidification structures of a given alloy can be obtained by varying experimental growth rates, it is desirable to understand the basic factors which control the formation and stability of these microstructures when conditions are altered. Directional solidification experiments are described and the results obtained in metallic and transparent organic systems are presented. Emphasis is on the characteristics of dendritic structures obtained under different solidification conditions. Specifically, the effect of the growth rate on the primary dendritic spacing, the secondary dendrite spacing, and the dendrite tip radius is discussed. It is shown that significant changes in the primary spacing are observed when a dendrite to cellular transition takes place at lower velocities. It is found that the primary cellular spacing is much smaller than the primary dendrite spacing so that a maximum in the primary spacing occurs as a function of velocity at the dendrite-cellular transition. A theoretical model is also described which quantitatively explains various microstructural features of dendritic and cellular structures.
The copper-niobium phase diagram has been under active debate; thus, a corroboratory experimental study is needed. In this investigation, the melts of Cu-Nb alloys at compositions ranging from 5 lo 86 wt% Nb were processed in different environments and solidified at relatively low rates of 50-75 C/s to determine liquidus temperatures and to study solidification behavior. For all samples processed under very clean conditions, only Nb dendrites in a Cu matrix were observed; while in the presents of oxygen impurities, the alloys containing 5-35 wt% Nb exhibited microstructure of Nb-rich spheroids and Nb dendrites in the Cu matrix. The results obtained from clean conditions are in fair agreement with the Cu-Nb phase diagram having an S-shaped, near-horizontal appearances of the liquidus. The formation of Nb-rich droplets at slow cooling rates is discussed in terms of a stable liquid miscibility gap induced by oxygen.
The copper-niobium phase diagram has been under active debate; thus, a corroboratory experimental study is needed. In this investigation, the melts of Cu-Nb alloys at compositions ranging from 5 to 86 wt pct Nb were processed in different environments and solidified at relatively low cooling rates of 50 to 75 C/s to determine liquidus temperatures and to study solidification behavior. For all samples processed under very clean conditions, only Nb dendrites in a Cu matrix were observed; while in the presence of oxygen impurities the alloys containing 5 to 35 wt pct Nb exhibited microstructure of Nb-rich spheroids and Nb dendrites in the Cu matrix. The results obtained from clean conditions are in fair agreement with the Cu-Nb phase diagram having an S-shaped, near-horizontal appearance of the liquidus. The formation of Nb- rich droplets at slow cooling rates is discussed in terms of a stable liquid miscibility gap induced by oxygen.
One of the greatest unresolved issues concerns the evolution of Mars early in its history; during the time period that accretion was winding down but the frequency of impacting debris was still heavy. Ancient cratered terrain that has only been moderately modified since the period of heavy bombardment covers about a quarter of the planet's surface but the environment during its formation is still uncertain. This terrain was dominantly formed by cratering. But unlike on the airless Moon, the impacting craters were strongly modified by other contemporary surface processes that have produced distinctive features such as: 1) dendritic channel networks, 2) rimless, flatfloored craters, 3) obliteration of most craters smaller than a few kilometers in diameter (except for post heavy-bombardment impacts), and 4) smooth intercrater plains. The involvement of water in these modification processes seems unavoidable, but interpretations of the surface conditions on early Mars range from the extremes of: 1) the "cold" model which envisions a thin atmosphere and surface temperatures below freezing except for local hydrothermal springs; and 2) the "warm" model, which invokes a thick atmosphere, seasonal temperatures above freezing in temperate and equatorial regions, and at least occasional precipitation as part of an active hydrological cycle. The nature of hydrologic cycles, if they occurred on Mars, would have been critically dependent on the environment. The resolution of where along this spectrum the actual environment of early Mars occurred is clearly a major issue, particularly because the alternate scenarios have much different implications about the possibility that life might have evolved on Mars. Additional information is contained in the original extended abstract.
One of the greatest unresolved issues concerns the evolution of Mars early in its history; during the time period that accretion was winding down but the frequency of impacting debris was still heavy. Ancient cratered terrain that has only been moderately modified since the period of heavy bombardment covers about a quarter of the planet's surface but the environment during its formation is still uncertain. This terrain was dominantly formed by cratering. But unlike on the airless Moon, the impacting craters were strongly modified by other contemporary surface processes that have produced distinctive features such as 1) dendritic channel networks, 2) rimless, flatfloored craters, 3) obliteration of most craters smaller than a few kilometers in diameter (except for post heavy-bombardment impacts), and 4) smooth intercrater plains. The involvement of water in these modification processes seems unavoidable, but interpretations of the surface conditions on early Mars range from the extremes of 1) the "cold" model which envisions a thin atmosphere and surface temperatures below freezing except for local hydrothermal springs; and 2) the "warm" model, which invokes a thick atmosphere, seasonal temperatures above freezing in temperate and equatorial regions, and at least occasional precipitation as part of an active hydrological cycle. The nature of hydrologic cycles, if they occurred on Mars, would have been critically dependent on the environment. The resolution of where along this spectrum the actual environment of early Mars occurred is clearly a major issue, particularly because the alternate scenarios have much different implications about the possibility that life might have evolved on Mars.
By studying the unidirectional growth of a metal-model material in microgravity, an attempt is made to characterize alloy solidification. Using holograms and supporting temperature measurements obtained during processing in the Fluids Experiment System (FES), the solute and thermal fields associated with the dendrite growth front and extraneous nucleation will be measured and compared to a theoretical (computational) model. Ground based supporting experiments include particle tracking to measure the velocity fields, and optical phase shift techniques (confocal optical signal processing, interferometry, and Schlieren) to study thermal and solutal fields.
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.
Using a base chilled configuration, conditions for the formation and prevention of segregation channels are studied in the ammonium chloride-water and lead-tin systems. Such channels develop when the rejected solute is less dense than the solvent and are therefore a result of density inversion, but slow (less than 5 rpm) rates of mold rotation, about axes inclined to the vertical by 20 to 30 deg, throughout the time of solidification, effectively prevent the formation or propagation of these channels. In experiments with artificially created or blocked channels, a simultaneous solute plume in the bulk liquid must be present in order for a channel to develop. The results indicate that channels originate not within the dendritic array, but immediately ahead of the growth front as a result of perturbation from the less dense boundary layer into the bulk liquid. The effect of mold movement is to translate laterally the bulk liquid relative to the growth front so that perturbations are sheared off. The nature of the liquid movement is considered and shown to be a function of the mold dimensions.
Within the oldest highland units on Mars, the record of crater degradation indicates that fluvial resurfacing was responsible for modifying the Noachian through middle-Hesperian crater population. Based on crater frequency in the Noachian cratered terrain, age/elevation relations suggest that the highest exposures of Noachian dissected and plateau units became stabilized first, followed by successively lower units. In addition, studies of drainage networks indicate that the frequency of Noachian channels is greatest at high elevations. Together, these observations provide strong evidence of atmospheric involvement in volatile recycling. The long time period of crater modification also suggests that dendritic highland drainage was not simply the result of sapping by release of juvenile water, because the varied geologic units as well as the elevation dependence of stability ages makes it unlikely that subsurface recycling could provide a continuous supply of water for channel formation by sapping. While such geomorphic constraints on volatile history have been established by crater counts and stratigraphic relations using the 1:2M photomosaic series, photogeologic age relationships at the detailed level are needed to establish a specific chronology of erosion and sedimentation. Age relations for discrete erosional slopes and depositional basins will help refine ages of fluvial degradation, assess effectiveness of aeolian processes, and provide a regional chronology of fluvial events.
The paper examines the growth parameter dependence of the longitudinal macrosegregation due to interdendritic thermosolutal convection during directional solidification of Pb-Sn alloys with a steady-state dendritic arrayed morphology. The experimentally observed longitudinal macrosegregation can be described by an empirical parameter, effective partition coefficient (kE), obtained from Cs = kEC0(1 - fs) super KI-1, where the original tin content is C0 and that corresponding to the fraction distance solidified (Fs) is Cs. Channel formation is strongly associated with the onset of thermosolutal convection in the interdendritic melt. The critical effective Rayleigh number for the onset of channel formation is about 0.07.
A research program is described which consisted of studying the effects of electrode cycling in very pure KOH solutions, with and without controlled additions of impurities, on oxide formation, oxygen evolution kinetics, oxygen reduction kinetics (including hydrogen peroxide formation), and changes in electrode structure. Bright platinum, platinized platinum, and Teflon-bonded platinum black electrodes were studied. Three main problem areas are identified: the buildup of a refractory anodic layer on prolonged cycling, which leads to a degradation of performance; the dissolution and subsequent deposition of dendritic platinum in the separator, leading to short-circuit ing and loss of electrocatalyst; and the disruptive effect of bubbling during gas evolution on charge. Each of these problem areas is analyzed, and remedial solutions are proposed.
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.