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At least 1,531 records · Page 85

Materials processing in low gravity

Several NASA facilities are available for low gravity experimentation: the Drop Facilities at NASA Marshall and the KC-135 at NASA Johnson. The use of these facilities allows for a rather inexpensive method of determining whether or not particular experiments will be worthwhile candidates for space experiments. Equipment currently available include various furnaces for the Drop Tube, the Drop Tower, and the KC-135. The furnaces for the Drop Tube include both an electron beam and electromagnetic levitation furnace. A vacuum furnace is used for the Drop Tower. Several furnaces used in performing KC-135 solidification experiments include the Automated Directional Solidification Furnace, the Isothermal Casting Furnace, the Rapid Melt/Rapid Quench and the Polymer/Video Furnaces.

Workman, Gary L.↗

Influence of convection on microstructure

The primary motivation for this research has been to determine the cause for space processing altering the microstructure of some eutectics, especially the MnBi-Bi eutectic. Prior experimental research at Grumman and here showed that the microstructure of MnBi-Bi eutectic is twice as fine when solidified in space or in a magnetic field, is uninfluenced by interfacial temperature gradient, adjusts very quickly to changes in freezing rate, and becomes coarser when spin-up/spin-down (accelerated crucible rotation technique) is used during solidification. Theoretical work at Clarkson predicted that buoyancy driven convection on earth could not account for the two fold change in fiber spacing caused by solidification in space. However, a lamellar structure with a planar interface was assumed, and the Soret effect was not included in the analysis. Experimental work at Clarkson showed that the interface is not planar, and that MnBi fibers project out in front of the Bi matrix on the order of one fiber diameter. Originally four primary hypotheses were to be tested under this current grant: (1) a fibrous microstructure is much more sensitive to convection than a lamellar microstructure, which was assumed in our prior theoretical treatment; (2) an interface with one phase projecting out into the melt is much more sensitive to convection than a planar interface, which was assumed in our prior theoretical treatment; (3) the Soret effect is much more important in the absence of convection and has a sufficiently large influence on microstructure that its action can explain the flight results; and (4) the microstructure is much more sensitive to convection when the composition of the bulk melt is off eutectic. As reported previously, we have learned that while a fibrous microstructure and a non-planar interface are more sensitive to convection than a lamellar microstructure with a planar interface, the influence of convection remains too small to explain the flight and magnetic field results. Similarly addition of the Soret effect does not explain the flight and magnetic field results.

Wilcox, William R.↗

Thrust chamber material technology program

This report covers work performed at Pratt & Whitney on development of copper-based materials for long-life, reusable, regeneratively cooled rocket engine thrust chambers. The program approached the goal of enhanced cyclic life through the application of rapid solidification to alloy development, to introduce fine dispersions to strengthen and stabilize the alloys at elevated temperatures. After screening of alloy systems, copper-based alloys containing Cr, Co, Hf, Ag, Ti, and Zr were processed by rapid-solidification atomization in bulk quantities. Those bulk alloys showing the most promise were characterized by tensile testing, thermal conductivity testing, and elevated-temperature, low-cycle fatigue (LFC) testing. Characterization indicated that Cu- 1.1 percent Hf exhibited the greatest potential as an improved-life thrust chamber material, exhibiting LCF life about four times that of NASA-Z. Other alloys (Cu- 0.6 percent Zr, and Cu- 0.6 percent Zr- 1.0 percent Cr) exhibited promise for use in this application, but needed more development work to balance properties.

Andrus, J. S.↗

Applications of containerless processing in the studies of metals and alloys

The use of containerless processing in nucleation and microstructural studies of alloys is reviewed in terms of approaches and recent results. Drop-tube studies of niobium based on a statistical approach are discussed, and experiments are described which permit the study of the solidification front across the surface of a specimen. The various alloys studied are reviewed in terms of facilitated observations of metastability, chemical homogeneity, and microstructural refinement. Heterogeneous nucleation is reported for a preexponential factor of 10 exp 27 and a critical free energy of 46-56kT. The theoretical relationship between undercooling and solidification velocity correlates with containerless test observations at large solute concentrations. Containerless processing is effective for studying the properties of liquid metals or accessing the metastable thermodynamic regime.

Bayuzick, R. J.↗

Microstructural and magnetic characterization of rapidly solidified and annealed Pt-Co-B alloys

Significant increases in intrinsic coercivity (Hic) of Pt-Co alloys have been obtained by the addition of boron and the application of rapid solidification processing. After rapid solidification by double anvil splat quenching with subsequent annealing at 650 C for 30 min, an alloy of Pt42Co45B13 exhibits an Hic as high as 14 kOe. Annealing of the Pt-Co-B influences the L1(0) superlattice structure and grain size of the matrix, the crystal structure and size of Co-boride precipitate, and the distribution of magnetic domain walls. A microstructural analysis shows that the maximum H(ic) occurs when Co borides, having the Co3B structure, are within the single magnetic domain size. The magnetic hardening mechanism in Pt-Co-B is believed to be a combination of inhibited magnetic domain nucleation and difficult reverse magnetic domain growth caused by the interaction of the magnetically anisotropic Co borides with the L1(0) Pt-Co matrix.

Qiu, N.↗

Segregation and convection in dendritic alloys

Microsegregation in dentritic alloys is discussed, including solidification with and without thermal gradient, the convection of interdendritic liquid. The conservation of momentum, energy, and solute is considered. Directional solidification and thermosolutal convection are discussed.

Poirier, D. R.↗

Shape selection criterion for cellular array during constrained growth of binary alloys - Need for low gravity experiment

Development of steady-state periodic cellular array is one of the critical problems in the study of nonlinear pattern formation during directional solidification of binary alloys. The criterion which establishes the values of cell tip radius and spacing under given growth condition is not known. Theoretical models, such as marginal stability and microscopic solvability, have been developed for purely diffusive regime. However, the experimental conditions where cellular structures are stable are precisely the ones where the convection effects are predominant. Thus, the critical data for meaningful evaluation of cellular array growth models can only be obtained by partial directional solidification and quenching experiments carried out in the low gravity environment of space.

Tewari, Surendra N.↗

The effectiveness of Coriolis dampening of convection during aircraft high-g arcs

Directional solidification data for metal samples in KC-135 parabolic maneuvers are examined to determine evidence for Coriolis dampening of convection. Microstructural and materials properties data are examined for iron carbon, immiscible, and superalloy systems. By comparison of low-g data and high-g data with those of one-g control samples, it is determined that there is no evidence that Coriolis dampening of convective flow is effective during the 1.8 g KC-135 high-g maneuvers. A first approximation model for the high-g arc is proposed. The model yields a centrifugal radius of 20,480 ft and an angular speed of 0.397 RPM. Comparison to centrifugal solidification experiments (for an equal acceleration) where Coriolis melt growth stabilization is significant indicates that the KC-135 high-g arc is less effective in dampening convection by a factor of 100. This large difference in Coriolis dampening of convection might be taken advantage of for experiments where separation of centrifugal acceeration and Coriolis acceleration is desirable.

Curreri, Peter A.↗

Effect of thermal convection on the shape of a solid-liquid interface

The effect of thermal convection on the shape of solid-liquid interface was investigated in experiments conducted in a transparent Bridgman-type directional solidification furnace. The relationship was numerically modeled using a standard 2D finite-difference approach, with the solid-liquid deformable interface approximated by a blocking-off technique. The directional solidification furnace was used with pure succinonitrile (which is also transparent) contained in a long square ampoule made of borosilicate glass. With the furnace in the vertical configuration, a flat interface was observed, in agreement with the model. On the other hand, a highly distorted interface was obtained in the horizontal configuration; the numerical results showed a strong recirculating cell in front of the interface due to natural thermal convection. The results indicate that thermal convection is responsible for the interface distortion.

Mennetrier, C.↗

Supercooling effects in Cu-10 wt pct Co alloys solidified at different cooling rates

Electromagnetic levitation and electron beam surface melting were employed to study the effects of supercooling and cooling rate on the solidification of Cu-10 wt pct Co alloys. Two major effects were observed in the supercooled alloys: the nucleation of a metastable copper-rich phase which contains 13 wt pct to 20 wt pct Co in samples supercooled between 105 and 150 K and liquid phase separation which occurs in samples supercooled 150 K or more. The microstructure of the electron beam melted surfaces consisted of very fine spheres which were similar to those of the sample supercooled more than 150 K but with a refined microstructure. The results indicate that a dynamic bulk supercooling of 150 K may exist in the molten pool during the solidification of electron beam melted surfaces.

Munitz, A.↗

FNAS modify matric and transparent experiments

Monotectic alloy materials are created by rapid melt/rapid solidification processing on the NASA KC-135. Separation of the uniform liquid into two liquids may occur by either of two processes; spinodal decomposition or nucleation followed by growth. In the first case, the liquid is unstable to composition waves, which form and grow, giving liquids of two different compositions. In the latter process discrete particles of the second liquid phase form via thermal fluctuations and then grow by diffusion. The two processes are very different, with the determining process being dictated by temperature, composition, and thermodynamic characteristics of the alloy. The first two quantities are process variables, while the third is determined by electronic interactions between the atoms in the alloy. In either case the initial alloy decomposition is followed by coarsening, resulting in growth of the particle size at nearly constant volume fraction. In particular, reduced gravity experiments on monotectic solutions have shown a number of interesting results in the KC-135. Monotectic solutions exhibit a miscibility gap in the liquid state, and consequently, gravity driven forces can dominate the solidification parameters at 1 g. In reduced gravity however, the distribution of the phases is different, resulting in new and interesting microstructures. The Rapid Melt/Rapid Quench Furnace allows one to melt a sample and resolidify it in one parabola of the KC-135's flight path, thus eliminating any accumulative influence of multiple parabolas to affect the microstructure of the material.

Smith, Guy A.↗

Study of Fluid Experiment System (FES)/CAST/Holographic Ground System (HGS)

The use of holographic and schlieren optical techniques for studying the concentration gradients in solidification processes has been used by several investigators over the years. The HGS facility at MSFC has been primary resource in researching this capability. Consequently, scientific personnel have been able to utilize these techniques in both ground based research and in space experiments. An important event in the scientific utilization of the HGS facilities was the TGS Crystal Growth and the casting and solidification technology (CAST) experiments that were flown on the International Microgravity Laboratory (IML) mission in March of this year. The preparation and processing of these space observations are the primary experiments reported in this work. This project provides some ground-based studies to optimize on the holographic techniques used to acquire information about the crystal growth processes flown on IML. Since the ground-based studies will be compared with the space-based experimental results, it is necessary to conduct sufficient ground based studies to best determine how the experiment worked in space. The current capabilities in computer based systems for image processing and numerical computation have certainly assisted in those efforts. As anticipated, this study has certainly shown that these advanced computing capabilities are helpful in the data analysis of such experiments.

Workman, Gary L.↗

Experimental observation of the influence of furnace temperature profile on convection and segregation in the vertical Bridgman crystal growth technique

Azulene-doped naphthalene was directionally solidified during the vertical Bridgman-Stockbarger technique. Doping homogeneity and convection were determined as a function of the temperature profile in the furnace and the freezing rate. Convection velocities were two orders of magnitude lower when the temperature increased with height. Rarely was the convection pattern axisymmetric, even though the temperature varied less than 0.1 K around the circumference of the growth ampoule. Correspondingly the cross sectional variation in azulene concentration tended to be asymmetric, especially when the temperature increased with height. This cross sectional variation changed dramatically along the ingot, reflecting changes in convection presumably due to the decreasing height of the melt. Although there was large scatter and irreproducibility in the cross sectional variation in doping, this variation tended to be least when the growth rate was low and the convection was vigorous. It is expected that compositional variations would also be small at high growth rates with weak convection and flat interfaces, although this was not investigated in the present experiments. Neither rotation of the ampoule nor deliberate introduction of thermal asymmetries during solidification had a significant influence on cross sectional variations in doping. It is predicted that slow directional solidification under microgravity conditions could produce greater inhomogeneities than on Earth. Combined use of microgravity and magnetic fields would be required to achieve homogeneity when it is necessary to freeze slowly in order to avoid constitutional supercooling.

Neugebauer, G. T.↗

Space Station Furnace Facility Core. Requirements definition and conceptual design study. Volume 2: Technical report. Appendix 6: Technical summary reports

The Space Station Furnace Facility (SSFF) is a modular facility for materials research in the microgravity environment of the Space Station Freedom (SSF). The SSFF is designed for crystal growth and solidification research in the fields of electronic and photonic materials, metals and alloys, and glasses and ceramics and will allow for experimental determination of the role of gravitational forces in the solidification process. The facility will provide a capability for basic scientific research and will evaluate the commercial viability of low-gravity processing of selected technologically important materials. The facility is designed to support a complement of furnace modules as outlined in the Science Capabilities Requirements Document (SCRD). The SSFF is a three rack facility that provides the functions, interfaces, and equipment necessary for the processing of the furnaces and consists of two main parts: the SSFF Core Rack and the two Experiment Racks. The facility is designed to accommodate two experimenter-provided furnace modules housed within the two experiment racks, and is designed to operate these two furnace modules simultaneously. The SCRD specifies a wide range of furnace requirements and serves as the basis for the SSFF conceptual design. SSFF will support automated processing during the man-tended operations and is also designed for crew interface during the permanently manned configuration. The facility is modular in design and facilitates changes as required, so the SSFF is adept to modifications, maintenance, reconfiguration, and technology evolution.

Source record↗

Research objectives, opportunities, and facilities for microgravity science

Microgravity Science in the U.S.A. involves research in fluids science, combustion science, materials science, biotechnology, and fundamental physics. The purpose is to achieve a thorough understanding of the effects of gravitational body forces on physical phenomena relevant to those disciplines. This includes the study of phenomena which are usually overwhelmed by the presence of gravitational body forces and, therefore, chiefly manifested when gravitational forces are weak. In the pragmatic sense, the research involves gravity level as an experimental parameter. Calendar year 1992 is a landmark year for research opportunities in low earth orbit for Microgravity Science. For the first time ever, three Spacelab flights will fly in a single year: IML-1 was launched on January 22; USML-1 was launched on June 25; and, in September, SL-J will be launched. A separate flight involving two cargo bay carriers, USMP-1, will be launched in October. From the beginning of 1993 up to and including the Space Station era (1997), nine flights involving either Spacelab or USMP carriers will be flown. This will be augmented by a number of middeck payloads and get away specials flying on various flights. All of this activity sets the stage for experimentation on Space Station Freedom. Beginning in 1997, experiments in Microgravity Science will be conducted on the Space Station. Facilities for doing experiments in protein crystal growth, solidification, and biotechnology will all be available. These will be joined by middeck-class payloads and the microgravity glove box for conducting additional experiments. In 1998, a new generation protein crystal growth facility and a facility for conducting combustion research will arrive. A fluids science facility and additional capability for conducting research in solidification, as well as an ability to handle small payloads on a quick response basis, will be added in 1999. The year 2000 will see upgrades in the protein crystal growth and fluids science facilities. From the beginning of 1997 to the fall of 1999 (the 'man-tended capability' era), there will be two or three utilization flights per year. Plans call for operations in Microgravity Science during utilization flights and between utilization flights. Experiments conducted during utilization flights will characteristically require crew interaction, short duration, and less sensitivity to perturbations in the acceleration environment. Operations between utilization flights will involve experiments that can be controlled remotely and/or can be automated. Typically, the experiments will require long times and a pristine environment. Beyond the fall of 1999 (the 'permanently-manned capability' era), some payloads will require crew interaction; others will be automated and will make use of telescience.

Bayuzick, Robert J.↗

Experiment/facility requirements document for the Space Station Furnace Facility. Section 1: Integrated configuration

The function of the Space Station Furnace Facility (SSFF) is to support materials research into the crystal growth and solidification processes of electronic and photonic materials, metals and alloys, and glasses and ceramics. To support this broad base of research requirements, the SSFF will employ a variety of furnace modules which will be operated, regulated, and supported by a core of common subsystems. Furnace modules may be reconfigured or specifically developed to provide unique solidification conditions for each set of experiments. The SSFF modular approach permits the addition of new or scaled-up furnace modules to support the evolution of the facility as new science requirements are identified. The SSFF Core is of modular design to permit augmentation for enhanced capabilities. The fully integrated configuration of the SSFF will consist of three racks with the capability of supporting up to two furnace modules per rack. The initial configuration of the SSFF will consist of two of the three racks and one furnace module. This Experiment/Facility Requirements Document (E/FRD) describes the integrated facility requirements for the Space Station Freedom (SSF) Integrated Configuration-1 (IC1) mission. The IC1 SSFF will consist of two racks: the Core Rack, with the centralized subsystem equipment; and the Experiment Rack-1, with Furnace Module-1 and the distributed subsystem equipment to support the furnace. The SSFF support functions are provided by the following Core subsystems: power conditioning and distribution subsystem (SSFF PCDS); data management subsystem (SSFF DMS); thermal control Subsystem (SSFF TCS); gas distribution subsystem (SSFF GDS); and mechanical structures subsystem (SSFF MSS).

Source record↗

Space Station Furnace Facility. Volume 2: Summary of technical reports

The Space Station Furnace Facility (SSFF) is a modular facility for materials research in the microgravity environment of the Space Station Freedom (SSF). The SSFF is designed for crystal growth and solidification research in the fields of electronic and photonic materials, metals and alloys, and glasses and ceramics, and will allow for experimental determination of the role of gravitational forces in the solidification process. The facility will provide a capability for basic scientific research and will evaluate the commercial viability of low-gravity processing of selected technologically important materials. In order to accommodate the furnace modules with the resources required to operate, SSFF developed a design that meets the needs of the wide range of furnaces that are planned for the SSFF. The system design is divided into subsystems which provide the functions of interfacing to the SSF services, conditioning and control for furnace module use, providing the controlled services to the furnace modules, and interfacing to and acquiring data from the furnace modules. The subsystems, described in detail, are as follows: Power Conditioning and Distribution Subsystem; Data Management Subsystem; Software; Gas Distribution Subsystem; Thermal Control Subsystem; and Mechanical Structures Subsystem.

Source record↗

A petrologic and ion microprobe study of a Vigarano Type B refractory inclusion - Evolution by multiple stages of alteration and melting

A Type B Ca-, Al-rich 6-m-diam inclusion (CAI) found in the Vigarano C3V chondrite was inspected using optical and scanning electron microscopies and ion microprobe analyses. It was found that the primary constituents of the CAI inclusion are (in percent), melilite (52), fassaite, (20), anorthite (18), spinel (10), and trace Fe-Ni metal. It is noted that, while many of the properties of the inclusion indicate solidification from a melt droplet, the Al-26/Mg-26 isotopic systematics and some textural relationships are incompatible with single-stage closed system crystallization of a homogeneous molten droplet, indicating that the history of this inclusion must have been more complex than melt solidification alone. Moreover, there was unusually high content of Na in melilite, suggesting that the droplet did not form by melting of pristine high-temperature nebular condensates.

Macpherson, Glenn J.↗