Engineering topics
Grugel, R. N.
Publications and source records attributed to Grugel, R. N..
Macrosegregation Resulting from Directional Solidification Through an Abrupt Change in Cross-Sections
Simulations of the directional solidification of two hypoeutectic alloys (Al-7Si alloy and Al-19Cu) and resulting macrosegregation patterns are presented. The casting geometries include abrupt changes in cross-section from a larger width of 9.5 mm to a narrower 3.2 mm width then through an expansion back to a width of 9.5 mm. The alloys were chosen as model alloys because they have similar solidification shrinkages, but the effect of Cu on changing the density of the liquid alloy is about an order of magnitude greater than that of Si. The simulations compare well with experimental castings that were directionally solidified in a graphite mold in a Bridgman furnace. In addition to the simulations of the directional solidification in graphite molds, some simulations were effected for solidification in an alumina mold. This study showed that the mold must be included in numerical simulations of directional solidification because of its effect on the temperature field and solidification. For the model alloys used for the study, the simulations clearly show the interaction of the convection field with the solidifying alloys to produce a macrosegregation pattern known as "steepling" in sections with a uniform width. Details of the complex convection- and segregation-patterns at both the contraction and expansion of the cross-sectional area are revealed by the computer simulations. The convection and solidification through the expansions suggest a possible mechanism for the formation of stray grains. The computer simulations and the experimental castings have been part of on-going ground-based research with the goal of providing necessary background for eventual experiments aboard the ISS. For casting practitioners, the results of the simulations demonstrate that computer simulations should be applied to reveal interactions between alloy solidification properties, solidification conditions, and mold geometries on macrosegregation. The simulations also presents the possibility of engineering the mold-material to avoid, or mitigate, the effects of thermosolutal convection and macrosegregation by selecting a mold material with suitable thermal properties, especially its thermal conductivity.
Primary Dendrite Arm Spacing and Trunk Diameter in Al-7-Weight-Percentage Si Alloy Directionally Solidified Aboard the International Space Station
Under a NASA-ESA collaborative research project, three Al-7-weight-percentage Si samples (MICAST-6, MICAST-7 and MICAST 2-12) were directionally solidified aboard the International Space Station to determine the effect of mitigating convection on the primary dendrite array. The samples were approximately 25 centimeters in length with a diameter of 7.8 millimeter-diameter cylinders that were machined from [100] oriented terrestrially grown dendritic Al-7Si samples and inserted into alumina ampoules within the Sample Cartridge Assembly (SCA) inserts of the Low Gradient Furnace (LGF). The feed rods were partially remelted in space and directionally solidified to effect the [100] dendrite-orientation. MICAST-6 was grown at 5 microns per second for 3.75 centimeters and then at 50 microns per second for its remaining 11.2 centimeters of its length. MICAST-7 was grown at 20 microns per second for 8.5 centimeters and then at 10 microns per second for 9 centimeters of its remaining length. MICAST2-12 was grown at 40 microns per second for 11 centimeters. The thermal gradient at the liquidus temperature varied from 22 to 14 degrees Kelvin per centimeter during growth of MICAST-6, from 26 to 24 degrees Kelvin per centimeter for MICAST-7 and from 33 to 31 degrees Kelvin per centimeter for MICAST2-12. Microstructures on the transverse sections along the sample length were analyzed to determine nearest-neighbor spacing of the primary dendrite arms and trunk diameters of the primary dendrite-arrays. This was done along the lengths where steady-state growth prevailed and also during the transients associated with the speed-changes. The observed nearest-neighbor spacings during steady-state growth of the MICAST samples show a very good agreement with predictions from the Hunt-Lu primary spacing model for diffusion controlled growth. The observed primary dendrite trunk diameters during steady-state growth of these samples also agree with predictions from a coarsening-based model. The radial macrosegregation and "steepling" caused by thermosolutal convection during terrestrial growth of the Al-7Si was not observed in the space-grown MICAST samples.
Macrosegregation Caused by Convection Associated with Directional Solidification through Cross-Section Change
Al-7 wt% Si and Pb-6 wt% Sb alloy samples were directionally solidified (DS), with liquid above and solid below and gravity pointing down, in cylindrical graphite crucibles through an abrupt cross-section change. Fraction eutectic distribution in the microstructure, primary dendrite spacing and primary dendrite trunk diameters have been measured in the DS samples in the vicinity of section change in order to examine the effect of convection associated with the combined influence of thermosolutal factors and solidification shrinkage. It is observed that convection not only produces extensive radial and axial macrosegregation near cross-section change, it also affects the dendritic array morphology. Primary dendrite spacing and primary dendrite trunk diameter, both, are influenced by this convection. In addition to the experimental results, preliminary results from a numerical model which includes solidification shrinkage and thermosolutal convection in the mushy zone in its analysis will also be presented
Evaluating Primary Dendrite Trunk Diameters in Directionally Solidified Al-Si Alloys
The primary dendrite trunk diameters of Al-Si alloys that were directionally solidified over a range of processing conditions have been measured. These data are analyzed with a model based primarily on an assessment of secondary dendrite arm dissolution in the mushy zone. Good fit with the experimental data is seen and it is suggested that the primary dendrite trunk diameter is a useful metric that correlates well with the actual solidification processing parameters. These results are placed in context with the limited results from the aluminium - 7 wt. % silicon samples directionally solidified aboard the International Space Station as part of the MICAST project.
Microstructure and Macrosegregation Study of Directionally Solidified Al-7Si Samples Processed Terrestrially and Aboard the International Space Station
This talk reports research that has been carried out under the aegis of NASA as part of a collaboration between ESA and NASA for solidification experiments on the International Space Station (ISS). The focus has been on the effect of convection on the microstructural evolution and macrosegregation in hypoeutectic Al‐Si alloys during directional solidification (DS). The DS‐experiments have been carried out under 1‐g at Cleveland State University (CSU) and under low‐g on the International Space Station (ISS). The thermal processing‐history of the experiments is well defined for both the terrestrially‐processed samples and the ISS‐processed samples. We have observed that the primary dendrite arm spacings of two samples grown in the low‐g environment of the ISS show good agreement with a dendrite‐growth model based on diffusion controlled growth. The gravity‐driven convection (i.e., thermosolutal convection) in terrestrially grown samples has the effect of decreasing the primary dendrite arm spacings and causes macrosgregation. In order to process DS‐samples aboard the ISS, dendritic‐seed crystals have to partially remelted in a stationary thermal gradient before the DS is carried out. Microstructural changes and macrosegregation effects during this period are described.
Comparison of Directionally Solidified Samples Solidified Terrestrially and Aboard the International Space Station
This article reports research that has been carried out under the aegis of NASA as part of a collaboration between ESA and NASA for solidification experiments on the International Space Station (ISS). The focus has been on the effect of convection on the microstructural evolution and macrosegregation in hypoeutectic Al-Si alloys during directional solidification (DS). Terrestrial DS-experiments have been carried out at Cleveland State University (CSU) and under microgravity on the International Space Station (ISS). The thermal processing-history of the experiments is well defined for both the terrestrially processed samples and the ISS-processed samples. As of this writing, two dendritic metrics was measured: primary dendrite arm spacings and primary dendrite trunk diameters. We have observed that these dendrite-metrics of two samples grown in the microgravity environment show good agreements with models based on diffusion controlled growth and diffusion controlled ripening, respectively. The gravity-driven convection (i.e., thermosolutal convection) in terrestrially grown samples has the effect of decreasing the primary dendrite arm spacings and causes macrosegregation. Dendrite trunk diameters also show differences between the earth- and space-grown samples. In order to process DS-samples aboard the ISS, the dendritic seed crystals were partially remelted in a stationary thermal gradient before the DS was carried out. Microstructural changes and macrosegregation effects during this period are described and have modeled.
Development of Ionic Liquid Based Epoxies for Carbon Fiber Composite Cryogenic Tanks
No abstract available
Novel Amalgams for In-Space Fabrication of Replacement Parts
Being able to fabricate replacement parts during extended space flight missions precludes the weight, storage volume, and speculation necessary to accommodate spares. Amalgams, widely used in dentistry, are potential candidates for fabricating parts in microgravity environments as they are moldable, do not require energy for melting, and do not pose fluid handling problems. Unfortunately, amalgams have poor tensile strength and the room temperature liquid component is mercury. To possibly resolve these issues a gallium-indium alloy was substituted for mercury and small steel fibers were mixed in with the commercial alloy powder. Subsequent microscopic examination of the novel amalgam revealed complete bonding of the components, and mechanical testing of comparable samples showed those containing steel fibers to have a significant improvement in strength. Experimental procedures, microstructures, and test results are presented and discussed in view of further improving properties.
Performance of "Waterless Concrete"
Waterless concrete consists of molten elementary sulfur and aggregate. The aggregates in a lunar environment will be lunar rocks and soil. Sulfur is present on the Moon in Troilite soil (FeS) and, by oxidation of the soil, iron and sulfur can be produced. Sulfur concrete specimens were cycled between liquid nitrogen (approx.]91 C) and room temperature (^21 C) to simulate exposure to a lunar environment. Cycled and control specimens were subsequently tested in compression at room temperatures (^21 C) and ^-101 C. Test results showed that due to temperature cycling, the compressive strength of cycled specimens was 20% of those non-cycled. This reduction in strength can be attributed to the large differences in thermal coefficients of expansion of the materials constituting the concrete which promoted cracking. Similar sulfur concrete mixtures were strengthened with short and long glass fibres. The lunar regolith simulant was melted in a 25 cc Pt- Rh crucible in a Sybron Thermoline high temperature MoSi2 furnace at melting temperatures of 1450 to 1600 C for times of 30 min to i hour. Glass fibres and small rods were pulled from the melt. The glass fibres were used to reinforce sulfur concrete plated to improve the flexural strength of the sulfur concrete. Beams strengthened with glass fibres showed to exhibit an increase in the flexural strength by as much as 45%.
Evaluation of Sulfur 'Concrete' for Use as a Construction Material on the Lunar Surface
Combining molten sulfur with any number of aggregate materials forms, when solid, a mixture having attributes similar, if not better, to conventional water-based concrete. As a result the use of sulfur "concrete" on Earth is well established, particularly in corrosive environments. Consequently, discovery of troilite (FeS) on the lunar surface prompted numerous scenarios about its reduction to elemental sulfur for use, in combination with lunar regolith, as a potential construction material; not requiring water, a precious resource, for its manufacture is an obvious advantage. However, little is known about the viability of sulfur concrete in an environment typified by extreme temperatures and essentially no atmosphere. The experimental work presented here evaluates the response of pure sulfur and sulfur concrete subjected to laboratory conditions that approach those expected on the lunar surface, the results suggesting a narrow window of application.
Microstructural Evaluation and Comparison of Solder Samples Processed Aboard the International Space Station
Samples from the In-Space Soldering Investigation (ISSI), conducted aboard the International Space Station (ISS), are being examined for post-solidification microstructural development and porosity distribution. In this preliminary study, the internal structures of two ISSI processed samples are compared. In one case 10cm of rosin-core solder was wrapped around a coupon wire and melted by conduction, whereas, in the other a comparable length of solder was melted directly onto the hot wire; in both cases the molten solder formed ellipsoidal blobs, a shape that was maintained during subsequent solidification. In the former case, there is clear evidence of porosity throughout the sample, and an accumulation of larger pores near the hot end that implies thermocapillary induced migration and eventual coalescence of the flux vapor bubbles. In the second context, when solder was fed onto the wire. a part of the flux constituting the solder core is introduced into and remains within the liquid solder ball, becoming entombed upon solidification. In both cases the consequential porosity, particularly at a solder/contact interface, is very undesirable. In addition to compromising the desired electrical and thermal conductivity, it promotes mechanical failure.
Sulfur 'Concrete' for Lunar Applications - Environmental Considerations
Commercial use of sulfur concrete on Earth is well established, particularly in corrosive, e.g., acid and salt, environments. Having found troilite (FeS) on the Moon raises the question of using extracted sulfur as a lunar construction material, an attractive alternative to conventional concrete as it does not require water. For the purpose of this Technical Memorandum, it is assumed that lunar ore is mined, refined, and the raw sulfur processed with appropriate lunar regolith to form, for example, bricks. With this stipulation, it is then noted that the viability of sulfur concrete in a lunar environment, which is characterized by lack of an atmosphere and extreme temperatures, is not well understood. The work presented here evaluates two sets of small sulfur concrete samples that have been prepared using JSC-1 lunar simulant as an aggregate addition. One set was subjected to extended periods in high vacuum to evaluate sublimation issues, and the other was cycled between room and liquid nitrogen temperatures to investigate their subsequent mechanical integrity. Results are presented from both investigations, discussed, and put into the context of the lunar environment.
Process Demonstration For Lunar In Situ Resource Utilization-Molten Oxide Electrolysis (MSFC Independent Research and Development Project No. 5-81)
The purpose of this Focus Area Independent Research and Development project was to conduct, at Marshall Space Flight Center, an experimental demonstration of the processing of simulated lunar resources by the molten oxide electrolysis process to produce oxygen and metal. In essence, the vision was to develop two key technologies, the first to produce materials (oxygen, metals, and silicon) from lunar resources and the second to produce energy by photocell production on the Moon using these materials. Together, these two technologies have the potential to greatly reduce the costs and risks of NASA s human exploration program. Further, it is believed that these technologies are the key first step toward harvesting abundant materials and energy independent of Earth s resources.
The Pore Formation and Mobility Investigation: A Summary of Conducted Research on the International Space Station
The Pore Formation and Mobility Investigation (PFMI) is being conducted in the Microgravity Science Glovebox (MSG) aboard the International Space Station (ISS) with the goal of understanding bubble generation and interactions during controlled directional solidification processing. Through the course of the experiments, beginning in September 2002, a number of key factors pertinent to solidification processing of materials in a microgravity environment have been directly observed, measured, and modeled. Though most experiments ran uninterrupted, on four separate occasions malfunctions to the PFMI hardware and software were experienced that required crew intervention, including in-space repair. Fortunately, each repair attempt was successful and restored the PFMI apparatus to a fully functional condition. Based on PFMI results and lessons learned, the intent of this presentation is to draw attention to the role ISS experiments/hardware can play in providing insight to potential fabrication processing techniques and repair scenarios that might arise during long duration space transport and/or on the lunar/Mars surface.
On-Orbit Testing of Materials and Processes
The Pore Formation and Mobility Investigation (PFMI) and the In-Space Soldering Investigation (ISSI) were conducted aboard the International Space Station (ISS) with the intent of promoting our understanding of materials processing in a low-gravity environment. The numerous experiments were conducted by telescience with the results evaluated by real time video and subsequently returned tapes and samples. In addition to discussing the experimental results and analysis the presentation will include an account of the ISS facilities (Microgravity Science Glovebox and Maintenance Work Area) used as well as some lessons-learned comments.
Experiments Conducted Aboard the International Space Station: The Pore Formation and Mobility Investigation (PFMI) and the In-Space Soldering Investigation (ISSI): A Current Study of Results
Experiments in support of the Pore Formation and Mobility Investigation (PFMI) and the In-Space Soldering Investigation (ISSI) were conducted aboard the International Space Station (ISS) with the goal of promoting our fundamental understanding of melting dynamics , solidification phenomena, and defect generation during materials processing in a microgravity environment. Through the course of many experiments a number of observations, expected and unexpected, have been directly made. These include gradient-driven bubble migration, thermocapillary flow, and novel microstructural development. The experimental results are presented and found to be in good agreement with models pertinent to a microgravity environment. Based on the space station results, and noting the futility of duplicating them in Earth s unit-gravity environment, attention is drawn to the role ISS experimentslhardware can play to provide insight to potential materials processing techniques and/or repair scenarios that might arise during long duration space transport and/or on the lunar/Mars surface.
Materials Research Conducted Aboard the International Space Station: Facilities Overview, Operational Procedures, and Experimental Outcomes
The Microgravity Science Glovebox (MSG) and Maintenance Work Area (MWA) are facilities aboard the International Space Station (ISS) that were used to successfully conduct experiments in support of, respectively, the Pore Formation and Mobility Investigation (PFMI) and the In-Space Soldering Investigation (ISSI). The capabilities of these facilities are briefly discussed and then demonstrated by presenting real-time and subsequently down-linked video-taped examples from the abovementioned experiments. Data interpretation, ISS telescience, some lessons learned, and the need of such facilities for conducting work in support of understanding materials behavior, particularly fluid processing and transport scenarios, in low-gravity environments is discussed.