Primary Dendrite Arm Spacing and Trunk Diameter in Al-7-weight-percentage Si Alloy Directionally Solidified Aboard the International Space Station
No abstract available
Tewari, Surendra↗
Engineering topics
Grugel, Richard
Publications and source records attributed to Grugel, Richard.
Macrosegregation and Grain Formation Caused by Convection Associated with Directional Solidification Through Cross-Section Increase
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.
Ghods, Masoud↗
Evaluation of Two Ionic Liquid-Based Epoxies from the MISSE-8 (Materials International Space Station Experiment-8) Sample Carrier
Two sets of epoxy mixtures, both containing the same ionic liquid (IL) based resin but utilizing two different curing agents, were evaluated after spending more than two years of continual space exposure outside of the International Space Station on the MISSE-8 sample rack. During this period the samples, positioned on nadir side, also experienced some 12,500 thermal cycles between approximately -40C and +40 C. Initial examination showed some color change, a miniscule weight variance, and no cracks or de-bonding from the sample substrate. Microscopic examination of the surface reveled some slight deformities and pitting. These observations, and others, are discussed in view of the ground-based control samples. Finally, the impetus of this study in terms of space applications is presented.
Rabenberg, Ellen↗
Evaluation of Primary Dendrite Arm Spacings from Aluminum-7wt% Silicon alloys Directionally Solidified aboard the International Space Station - Comparison with Theory
Aluminum – 7wt% silicon alloys were directionally solidified in the microgravity environment aboard the International Space Station as part of the “MIcrostructure Formation in CASTing of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions” (MICAST) European led program. Cross-sections of the sample during periods of steady-state growth were metallographically prepared from which the primary dendrite arm spacing (lambda 1) was measured. These spacings were found to be in reasonable agreement with the Hunt-Lu model which assumes a diffusion-controlled, convectionless, environment during controlled solidification. Deviation from the model was found and is attributed to gravity-independent thermocapillary convection where, over short distances, the liquid appears to have separated from the crucible wall.
Angart, Samuel↗
Primary Dendrite Arm Spacings in Al-7Si Alloy Directionally Solidified on the International Space Station
Samples from directionally solidified Al- 7 wt. % Si have been analyzed for primary dendrite arm spacing (lambda) and radial macrosegregation. The alloy was directionally solidified (DS) aboard the ISS to determine the effect of mitigating convection on lambda and macrosegregation. Samples from terrestrial DS-experiments thermal histories are discussed for comparison. In some experiments, lambda was measured in microstructures that developed during the transition from one speed to another. To represent DS in the presence of no convection, the Hunt-Lu model was used to represent diffusion controlled growth under steady-state conditions. By sectioning cross-sections throughout the entire length of a solidified sample, lambda was measured and calculated using the model. During steady-state, there was reasonable agreement between the measured and calculated lambda's in the space-grown samples. In terrestrial samples, the differences between measured and calculated lambda's indicated that the dendritic growth was influenced by convection.
Angart, Samuel↗
Evaluation of Carbon Composite Overwrap Pressure Vessels Fabricated Using Ionic Liquid Epoxies Project
The intent of the work proposed here is to ascertain the viability of ionic liquid (IL) epoxy based carbon fiber composites for use as storage tanks at cryogenic temperatures. This IL epoxy has been specifically developed to address composite cryogenic tank challenges associated with achieving NASA's in-space propulsion and exploration goals. Our initial work showed that an unadulterated ionic liquid (IL) carbon-fiber composite exhibited improved properties over an optimized commercial product at cryogenic temperatures. Subsequent investigative work has significantly improved the IL epoxy and our first carbon-fiber Composite Overwrap Pressure Vessel (COPV) was successfully fabricated. Here additional COPVs, using a further improved IL epoxy, will be fabricated and pressure tested at cryogenic temperatures with the results rigorously analyzed. Investigation of the IL composite for lower pressure liner-less cryogenic tank applications will also be initiated. It is expected that the current Technology Readiness Level (TRL) will be raised from about TRL 3 to TRL 5 where unambiguous predictions for subsequent development/testing can be made.
Grugel, Richard↗
NASA's Microgravity Materials Science Program: A Review of Experimental Investigations
No abstract available
Grugel, Richard↗
NASA's Microgravity Materials Science Program - A Review of Experimental Investigations
NASA was not the first to understand and utilize the benefits of processing materials in a microgravity environment.
Grugel, Richard↗
Overview of NASA's Microgravity Materials Research Program
The NASA microgravity materials program is dedicated to conducting microgravity experiments and related modeling efforts that will help us understand the processes associated with the formation of materials. This knowledge will help improve ground based industrial production of such materials. The currently funded investigations include research on the distribution of dopants and formation of defects in semiconductors, transitions between columnar and dendritic grain morphology, coarsening of phase boundaries, competition between thermally and kinetically favored phases, and the formation of glassy vs. crystalline material. NASA microgravity materials science investigators are selected for funding either through a proposal in response to a NASA Research Announcement or by participation in a team proposing to a foreign agency research announcement. In the latter case, a US investigator participating in a successful proposal to a foreign agency can then apply to NASA for funding of an unsolicited proposal. The program relies on cooperation with other aerospace partners from around the world. The ISS facilities used for these investigations are provided primarily by partnering with foreign agencies and in most cases the US investigators are working as a part of a larger team studying a specific area of materials science. The following facilities are to be utilized for the initial investigations. The ESA provided Low Gradient Facility and the Solidification and Quench Inserts to the Materials Research Rack/Materials Science Laboratory are to be used primarily for creating bulk samples that are directionally solidified or quenched from a high temperature melt. The CNES provided DECLIC facility is used to observe morphological development in transparent materials. The ESA provided Electro-Magnetic Levitator (EML) is designed to levitate, melt and then cool samples in order to study nucleation behavior. The facility provides conditions in which nucleation of the solid is not triggered from the wall and in which fluid flows in the sample can be controlled and manipulated. These conditions allow scientists ideal conditions for understanding the relative amounts and distribution of different phases that form in the solid. Finally, the Coarsening of Solid Liquid Melts hardware allows quenching of low temperature samples in the Microgravity Science Glovebox.
Downey, James Patton↗
Primary Dendrite Array Morphology: Observations from Ground-based and Space Station Processed Samples
Influence of natural convection on primary dendrite array morphology during directional solidification is being investigated under a collaborative European Space Agency-NASA joint research program, "Microstructure Formation in Castings of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions (MICAST)". Two Aluminum-7 wt pct Silicon alloy samples, MICAST6 and MICAST7, were directionally solidified in microgravity on the International Space Station. Terrestrially grown dendritic monocrystal cylindrical samples were remelted and directionally solidified at 18 K/cm (MICAST6) and 28 K/cm (MICAST7). Directional solidification involved a growth speed step increase (MICAST6-from 5 to 50 micron/s) and a speed decrease (MICAST7-from 20 to 10 micron/s). Distribution and morphology of primary dendrites is currently being characterized in these samples, and also in samples solidified on earth under nominally similar thermal gradients and growth speeds. Primary dendrite spacing and trunk diameter measurements from this investigation will be presented.
Tewari, Surendra↗
Making High-Tensile-Strength Amalgam Components
Structural components made of amalgams can be made to have tensile strengths much greater than previously known to be possible. Amalgams, perhaps best known for their use in dental fillings, have several useful attributes, including room-temperature fabrication, corrosion resistance, dimensional stability, and high compressive strength. However, the range of applications of amalgams has been limited by their very small tensile strengths. Now, it has been discovered that the tensile strength of an amalgam depends critically on the sizes and shapes of the particles from which it is made and, consequently, the tensile strength can be greatly increased through suitable choice of the particles. Heretofore, the powder particles used to make amalgams have been, variously, in the form of micron-sized spheroids or flakes. The tensile reinforcement contributed by the spheroids and flakes is minimal because fracture paths simply go around these particles. However, if spheroids or flakes are replaced by strands having greater lengths, then tensile reinforcement can be increased significantly. The feasibility of this concept was shown in an experiment in which electrical copper wires, serving as demonstration substitutes for copper powder particles, were triturated with gallium by use of a mortar and pestle and the resulting amalgam was compressed into a mold. The tensile strength of the amalgam specimen was then measured and found to be greater than 10(exp 4) psi (greater than about 69 MPa). Much remains to be done to optimize the properties of amalgams for various applications through suitable choice of starting constituents and modification of the trituration and molding processes. The choice of wire size and composition are expected to be especially important. Perusal of phase diagrams of metal mixtures could give insight that would enable choices of solid and liquid metal constituents. Finally, whereas heretofore, only binary alloys have been considered for amalgams, ternary additions to liquid or solid components should be considered as means to impart desired properties to amalgams.
Grugel, Richard↗
Materials Processing in Space: Model Experiments aboard the International Space Station
Direct observation of fluid flow, bubble movement and solidification during controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus in the glovebox facility (GBX) on board the ISS. Experimental processing parameters of temperature gradient and translation speed, as well as camera settings, were remotely monitored and manipulated from the ground Telescience Center (TSC) at the Marshall Space Flight Center. Real time visualization of the controlled directional melt back and resolidification reveals a number of microgravity dependent phenomena otherwise masked by Earth s gravity. These and some initial analysis of the observed events is presented.
Grugel, Richard↗
SUBSA and PFMI Transparent Furnace Systems Currently in use in the International Space Station Microgravity Science Glovebox
The Solidification Using a Baffle in Sealed Ampoules (SUBSA) and Pore Formation and Mobility Investigation (PFMI) furnaces were developed for operation in the International Space Station (ISS) Microgravity Science Glovebox (MSG). Both furnaces were launched to the ISS on STS-111, June 4, 2002, and are currently in use on orbit. The SUBSA furnace provides a maximum temperature of 850 C and can accommodate a metal sample as large as 30 cm long and 12mm in diameter. SUBSA utilizes a gradient freeze process with a minimum cooldown rate of 0.5C per min, and a stability of +/- 0.15C. An 8 cm long transparent gradient zone coupled with a Cohu 3812 camera and quartz ampoule allows for observation and video recording of the solidification process. PFMI is a Bridgman type furnace that operates at a maximum temperature of 130C and can accommodate a sample 23cm long and 10mm in diameter. Two Cohu 3812 cameras mounted 90 deg apart move on a separate translation system which allows for viewing of the sample in the transparent hot zone and gradient zone independent of the furnace translation rate and direction. Translation rates for both the cameras and furnace can be specified from 0.5micrometers/sec to 100 micrometers/sec with a stability of +/-5%. The two furnaces share a Process Control Module (PCM) which controls the furnace hardware, a Data Acquisition Pad (DaqPad) which provides signal condition of thermal couple data, and two Cohu 3812 cameras. The hardware and software allow for real time monitoring and commanding of critical process control parameters. This paper will provide a detailed explanation of the SUBSA and PFMI systems along with performance data and some preliminary results from completed on-orbit processing runs.
Spivey, Reggie A.↗
Magnetic Field Applications in Semiconductor Crystal Growth and Metallurgy
The Traveling Magnetic Field (TMF) technique, recently proposed to control meridional flow in electrically conducting melts, is reviewed. In particular, the natural convection damping capability of this technique has been numerically demonstrated with the implication of significantly improving crystal quality. Advantages of the traveling magnetic field, in comparison to the more mature rotating magnetic field method, are discussed. Finally, results of experiments with mixing metallic alloys in long ampoules using TMF is presented
Mazuruk, Konstantin↗
Effects of Traveling Magnetic Field on Dynamics of Solidification
TMF is based on imposing a controlled phase-shift in a train of electromagnets, forming a stack. Thus, the induced magnetic field can be considered to be travelling along the axis of the stack. The coupling of this traveling wave with an electrically conducting fluid results in a basic flow in a form of a single axisymmetric roll. The magnitude and direction of this flow can be remotely controlled. Furthermore, it is possible to localize the effect of this force field though activating only a number of the magnets. This force field generated in the fluid can, in principle, be used to control and modify convection in the molten material. For example, it can be used to enhance convective mixing in the melt, and thereby modify the interface shape, and macrosegregation. Alternatively, it can be used to counteract thermal and/or solutal buoyancy forces. High frequency TMF can be used in containerless processing techniques, such as float zoning, to affect the very edge of the fluid so that Marangoni flow can be counter balanced. The proposed program consists of basic fundamentals and applications. Our goal in conducting the following experiments and analyses is to establish the validity of TMF as a new tool for solidification processes. Due to its low power consumption and simplicity of design, this tool may find wide spread use in a variety of space experiments. The proposed ground based experiments are intended to establish the advantages and limitations of employing this technique. In the fundamentals component of the proposed program, we will use theoretical tools and experiments with mercury to establish the fundamental aspects of TMF-induced convection through a detailed comparison of theoretical predictions and experimental measurements of flow field. In this work, we will conduct a detailed parametric study involving the effects of magnetic field strength, frequency, wave vector, and the fluid geometry. The applications component of this work will be focused on investigating the effect of TMF on the following solidification and pre-directional solidification processes: (1) Bridgman growth of Ga:Ge with the goal of counteracting the buoyancy-driven convection; (2) Mixing of Pb-Ga and Pb-Sn alloys with the aim of initiating and maintaining a uniform melt prior to solidification processing; and (3) Float Zone growth with the aim of identifying, through simulations and model experiments, conditions needed to counteract Marangoni flow in a microgravity environment. The proposed research has strong relevance to microgravity research and the objectives of the NRA. TMF can provide a unique and accurate mechanism for generation and control of desirable flow patterns for microgravity research. These attributes have significant relevance to 1) Alloy mixing prior to solidification in a microgravity environment. TMF can provide this mixing with a low level of power consumption; (2) TMF can offset the deleterious effects of Marangoni convection in microgravity containerless processing. Thus, TMF can be instrumental in further understanding this phenomena; (3) Generation of controlled flows will allow the investigation of the effect of these flows on growth morphology and growth kinetics; and (4) On Earth, TMF has the potential to significantly counter-balance thermosolutal convection, thereby creating conditions similar to those obtained in microgravity. Once demonstrated, this new tool for use in solidification has the strong potential to find applications in a host of microgravity material research projects.
Mazuruk, Konstantin↗