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High gradient allows rapid growth rates in directionally-solidified eutectic alloys. Furnace design permits cost reductions in directional solidification process through its increased solidification rates, which reduces melt/mold interaction. It produces structural engineering materials for any application requiring properties directionally-solidified eutectic materials.
The role that a munition's structural response plays in the ignition process and the development of violent reactions and detonations is explored. The munition's structural response is identified as one of the factors that influences reaction violence. If the structural response of a round is known, this knowledge can be used to redstruce the probability that a large explosion would result from the sequential detonation of individual rounds within a large storage array. The response of an acceptor round was studied. The castings fail in the same manner regardless of whether or not there is a fill material present in the round. These failures are caused by stress waves which are transformed from compressive waves to tensile waves by reflection as the impact energy moves around the casting. Since these waves move in opposite directions around the projectile circumference and collide opposite the point of impact, very high tensile forces are developed which can crack the casing.
Case studies were made of the graphite structures in cast iron. The form, size, distribution, and direction of the structures are described. Microscopic and stereoscopic techniques are discussed.
A program was performed to address the mechanical and environmental needs of Stirling engine heater head and regenerator housing components, while reducing the dependence on strategic materials. An alloy was developed which contained no strategic elemental additions per se. The base is iron with additions of manganese, molybdenum, carbon, silicon, niobium, and ferro-chromium. Such an alloy should be producible on a large scale at very low cost. The resulting alloy, designated as NASAUT 4G-Al, contained 15 Mn, 15 Cr, 2 Mo, 1.5 C, 1.0 Si, 1.0 Nb (in weight percent) with a balance of Fe. This alloy was optimized for chemistry, based upon tensile strength, creep-rupture strength, fracture behavior, and fatigue resistance up to 800 C. Alloys were also tested for environmental compatibility. The microstructure and mechanic properties (including hardness) were assessed in the as-cast condition and following several heat treatments, including one designed to simulate a required braze cycle. The alloy was fabricated and characterized in the form of both equiaxed and columnar-grained castings. The columnar grains were produced by directional solidification, and the properties were characterized in both the longitudinal and transverse orientations. The NASAUT 4G-Al alloy was found to be good in cyclic-oxidation resistance and excellent in both hydrogen and hot-corrosion resistance, especially in comparison to the baseline XF-818 alloy. The mechanical properties of yield strength, stress-rupture life, high-cycle-fatigue resistance, and low-cycle-fatigue resistance were good to excellent in comparison to the current alloy for this application, HS-31 (X-40), with precise results depending in a complex manner on grain orientation and temperature. If required, the ductility could be improved by lowering the carbon content.
An experiment was conducted to understand the physical mechanisms that lead to the formation of scallops on swept wings. Icing runs were performed on a NACA 0012 swept wing tip at 45 deg, 30 deg, and 15 deg sweep angles. A baseline case was chosen and direct measurements of scallop height and spacing, castings, video data and close-up photographic data were obtained. The results showed the scallops are made of glaze ice feathers that grow from roughness elements that have reached a minimum height and are located beyond a given distance from the attachment line. This distance depends on tunnel conditions and sweep angle, and is the critical parameter in the formation of scallops. It determines if complete scallops, incomplete scallops or no scallops are going to be formed. The mechanisms of growth for complete and incomplete scallops were identified. The effect of velocity, temperature and LWC on scallop formation was studied. The possibility that cross flow instability may be the physical mechanism that triggers the growth of roughness elements into glaze ice feathers is examined.
Pairs of azimuthal intensity decrements at near-symmetric locations have been seen in a number of protoplanetary disks. They are most commonly interpreted as the two shadows cast by a highly misaligned inner disk. Direct evidence of such an inner disk, however, remains largely illusive, except in rare cases. In 2012, a pair of such shadows were discovered in scattered-light observations of the near face-on disk around 2MASS J16042165- 2130284, a transitional object with a cavity ∼60 au in radius. The star itself is a “dipper,” with quasi-periodic dimming events on its light curve, commonly hypothesized as caused by extinctions by transiting dusty structures in the inner disk. Here, we report the detection of a gas disk inside the cavity using Atacama Large Millimeter/ submillimeter Array (ALMA) observations with ∼0".2 angular resolution. A twisted butterfly pattern is found in the moment 1 map of the CO (3–2) emission line toward the center, which is the key signature of a high misalignment between the inner and outer disks. In addition, the counterparts of the shadows are seen in both dust continuum emission and gas emission maps, consistent with these regions being cooler than their surroundings. Our findings strongly support the hypothesized misaligned inner disk origin of the shadows in the J1604-2130 disk. Finally, the inclination of the inner disk would be close to −45° in contrast with 45°; it is possible that its internal asymmetric structures cause the variations on the light curve of the host star.
Technology innovations directed at the advanced development of a potentially low cost and weldable graphite/magnesium metal matrix composites (MMC) through near net shape pressure casting are described. These MMC components uniquely have built-in metallic inserts to provide an innovative approach for joining or connecting other MMC components through conventional joining techniques such as welding, brazing, mechanical fasteners, etc. Moreover, the metallic inserts trapped within the MMC components can be made to transfer the imposed load efficiently to the continuous graphite fiber reinforcement thus producing stronger, stiffer, and more reliable MMC components. The use of low pressure near net shape casting is economical compared to other MMC fabrication processes. These castable and potentially weldable MMC components can provide great payoffs in terms of high strength, high stiffness, low thermal expansion, lightweight, and easily joinable MMC components for several future NASA space structural, industrial, and commercial applications.
Cost benefit studies were conducted on six advanced materials and processes technologies applicable to commercial engines planned for production in the 1985 to 1990 time frame. These technologies consisted of thermal barrier coatings for combustor and high pressure turbine airfoils, directionally solidified eutectic high pressure turbine blades, (both cast and fabricated), and mixers, tail cones, and piping made of titanium-aluminum alloys. A fabricated titanium fan blisk, an advanced turbine disk alloy with improved low cycle fatigue life, and a long-life high pressure turbine blade abrasive tip and ceramic shroud system were also analyzed. Technologies showing considerable promise as to benefits, low development costs, and high probability of success were thermal barrier coating, directionally solidified eutectic turbine blades, and abrasive-tip blades/ceramic-shroud turbine systems.
The proposed design for the light duty diesel is an in-line four cylinder spark assisted diesel engine mounted transversely in the front of the vehicle. The engine has a one piece cylinder head, with one intake valve and one exhaust valve per cylinder. A flat topped piston is used with a cylindrical combustion chamber recessed into the cylinder head directly under the exhaust valve. A single ceramic insert is cast into the cylinder head to insulate both the combustion chamber and the exhaust port. A similar ceramic insert is cast into the head to insulate the intake port. A ceramic faceplate is pressed into the combustion face of the head to insulate the face of the head from hot combustion gas. The valve seats are machined directly into the ceramic faceplate for the intake valve and into the ceramic exhaust pot insert for the exhaust valve. Additional ceramic applications in the head are the use of ceramic valve guides and ceramic insulated valves. The ceramic valve guides are press fit into the head and are used for increased wear resistance. The ceramic insulated valves are conventional valves with the valve faces plasma spray coated with ceramic for insulation.
Polyimide P10P and its processing technique apply to most high temperature plastic products, devices and castings. Prepolymer, when used as varnish, impregnates fibers directly and is able to be processed into advanced composities. Material may also be used as molding powder and adhesive.
Experiment objectives, design/operational concepts, and final results are summarized for six materials science experiments conducted during the second space processing applications rocket mission flown by NASA. The individual experiments discussed are: (1) solidification of Pb-Sb eutectic; (2) feasibility of producing closed-cell metal foams; (3) direct observation of dendrite remelting and macrosegregation in castings; (4) agglomeration in immiscible liquids; (5) casting dispersion - strengthened composites at zero gravity; and (6) solidification behavior of Al-In alloys under zero gravity conditions.
The transverse, low cycle fatigue properties were determined for directionally solidified and single crystal samples of a cast nickel-base alloy proposed for use in space propulsion systems in pure or partial high pressure hydrogen environments at elevated temperatures. The test temperature was 760 C (1400F) and the pressure of the gaseous hydrogen was 34.5 MPa (5000 psig). Low cycle fatique life was established by strain controlled testing using smooth specimens and a servohydraulic closed-loop test machine modified with a high pressure environmental chamber. Results and conclusions are discussed.
During dendritic solidification liquid flow is induced both by buoyancy forces and solidification shrinkage. There is strong evidence that the major reason for the liquid flow is the former, i.e., thermosolutal convection. In the microgravity environment, it is thought that the thermosolutal convection will be greatly diminished so that convection will be confined mainly to the flow of interdendritic liquid required to satisfy the solidification shrinkage. An attempt is made to provide improved models of dendritic solidification with emphasis on convection and macrosegregation. Macrosegregation is an extremely important subject to the commercial casting community. The simulation of thermosolutal convection in directionally solidified (DS) alloys is described. A linear stability analysis was used to predict marginal stability curves for a system that comprises a mushy zone underlying an all-liquid zone. The supercritical thermosolutal convection in directionally solidified dendritic alloys was also modeled. The model assumes a nonconvective initial state with planar and horizontal isotherms and isoconcentration that move upward at a constant solidification velocity. Results are presented for systems involving lead-tin alloys and show significant differences with results of plane-front solidification.
Direct numerical simulations (DNS) of the Navier-Stokes equations are employed to explore the effects of suction holes on transition in a laminar flat plate boundary layer. The Navier-Stokes equations are cast in vorticity-velocity form. Periodicity is imposed in spanwise direction; all other spatial derivatives are discretized with fourth order compact differences. An explicit fourth order Runge-Kutta scheme is employed for the time-integration of the vorticity transport equations. Suction is applied through a row of holes aligned in spanwise direction. For low suction strengths, each hole generates a pair of stable streamwise vortices. When the suction strength exceeds a critical value, the vortices become unstable. For high suction strengths, vortex shedding occurs right at the suction holes. Our numerical findings agree well with experimental observations.
The quality of silicon cast by present techniques is limited by the presence of dislocations and grain boundaries in unseeded growth and by cellular structures with dislocation networks in the case of the seeded growth. To address these concerns, a new method of directional solidification called the oscillating crucible technique (OCT) is developed. During growth, a carbon crucible is oscillated to provide for effective stirring of the melt. This growth technique (seeded growth only), along with material characterization and solar-cell fabrication and testing, is described. Solar-cell efficiencies of up to 13 percent at 100 mW/sq cm area obtained in the single crystalline areas. Minority-carrier diffusion lengths exceeding 100 microns are measured even in the polycrystalline areas of the wafers. Limitations of the present setup and possible future improvements are discussed.
The US team of the European led "MIcrostructure Formation in CASTing of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions" (MICAST) program recently received a third Aluminum - 7wt% silicon alloy that was processed in the microgravity environment aboard the International Space Station. The sample, designated MICAST#2-12, was directionally solidified in the Solidification with Quench Furnace (SQF) at a constant rate of 40micometers/s through an imposed temperature gradient of 31K/cm. Procedures taken to evaluate the state of the sample prior to sectioning for metallographic analysis are reviewed and rational for measuring the microstructural constituents, in particular the primary dendrite arm spacing (Lambda (sub1)), is given. The data are presented, put in context with the earlier samples, and evaluated in view of a relevant theoretical model.
A high torque motor with improved servo mechanism is reported. Armature windings are cast into an epoxy cylinder and armature conductors are integrally cast with an aluminum mounting ring which provides thermal conductance directly into the structure. This configuration eliminates magnetic hysteresis because there is no relative motion between the rotating magnetic field and any stationary iron. The absence of destabilization forces provides a fast electrical response compared with a typical torquer of conventional construction.
The experiment objectives, design/operational concepts, and final results of each of nine scientific experiments conducted during the first Space Processing Applications Rocket (SPAR) flight are summarized. The nine individual SPAR experiments, covering a wide and varied range of scientific materials processing objectives, were entitled: solidification of Pb-Sb eutectic, feasibility of producing closed-cell metal foams, characterization of rocket vibration environment by measurement of mixing of two liquids, uniform dispersions of crystallization processing, direct observation of solidification as a function of gravity levels, casting thoria dispersion-strengthened interfaces, contained polycrystalline solidification, and preparation of a special alloy for manufacturing of magnetic hard superconductor under zero-g environment.