Engineering topics
Publications and source records attributed to Papazian, J. M..
In zero gravity, alined columnar microstructures form at expense of equiaxed growth. Preferential crystal growth occurs in solidification chamber consisting of semicylindrical copper chill block brazed to stainless steel top plate. Method is best utilized in castings where directional dependence of physical properties is beneficial, as in turbine blades.
The effect of gravity on the columnar-to-equiaxed microstructural transition was studied in small samples of NH4Cl-H2O. The behavior of the samples during laboratory (one gravity) experiments was contrasted with their behavior during a (low gravity) sounding rocket flight. In one gravity, the columnar zone accounted for 25 to 100 pct of the structure, depending on the superheat and orientation of the chill. Grain multiplication occurred by showering and by convection induced dendrite arm remelting. Convection was caused by both thermal gradients and solutal gradients. In low gravity, however, completely columnar structures were obtained; all grain multiplication mechanisms were entirely suppressed. Reduced gravity also modified the thermal conditions and caused the liquid to cool more slowly. This resulted in a steeper temperature gradient in the liquid ahead of the solidification interface. 'Big bang' type nucleation occurred in two of the samples, distributing nuclei throughout the liquid. Despite this, an equiaxed zone did not form, indicating that the most significant effect of low gravity on this experiment was modification of the thermal conditions.
A model has been developed for the prediction of bubble departure radii from flat solidification interfaces, including the effect of thermocapillary forces. Under normal gravity conditions, the necessary gas bubble radius required for departure from a CBr4 solidification interface is predicted to be approximately 1/2 mm in agreement with measured values. Under microgravity conditions, however, where surface forces predominate, the model predicts a seemingly prohibitive value of 40 mm. This result is at least in agreement with the microgravity tests conducted on the NASA SPAR I and SPAR III sounding rockets (1978) where the bubbles were not larger than 2 mm in radius and no bubble detachment was observed.
The trapping and behavior of gas bubbles were studied during low-gravity solidification of carbon tetrabromide, a transparent metal-model material. The experiment was performed during a NASA-sponsored sounding rocket flight and involved gradient freeze solidification of a gas-saturated melt. Gas bubbles were evolved at the solid-liquid interface during the low-gravity interval. No large-scale thermal migration of bubbles, bubble pushing by the solid-liquid interface, or bubble detachment from the interface were observed during the low-gravity experiment. A unique bubble motion-fluid flow event occurred in one specimen: a large bubble moved downward and caused some circulation of the melt. The gas bubbles that were trapped by the solid in commercial-purity material formed voids that had a cylindrical shape, in contrast to the spherical shape that had been observed in a prior low-gravity experiment. These shapes were not influenced by the gravity level (0.0001 g-0 vs g-0), but were dependent upon the initial temperature gradient. In higher purity material, however, the shape of the voids changed from cylindrical in 1g to spherical in low gravity.
Ground-based methods for pretesting qualitatively the thermocapillary movement of gas bubbles in a liquid to be used in space processing are discussed. Theoretical considerations are shown to require the use of a thin, enclosed, horizontal liquid film in order that the bubbles move faster than the bulk convection of the liquid, with insulating boundaries to prevent the onset of instabilities. Experimental realizations of horizontal cells in which to test the thermocapillary movement of bubbles in sheets of molten glass heated from below and organic melts in tubes heated from both ends are briefly described and the results of experiments are indicated.
The trapping and behavior of gas bubbles were studied during low gravity solidification of carbon tetrabromide. The flight experiments were performed during two sounding rocket flights (SPAR 1 and SPAR 3) and involved gradient freeze solidification of gas saturated melts. Gas bubbles were evolved at the solid-liquid interfaces during the low gravity intervals. No large-scale thermal migration of bubbles, bubble pushing by the solid-liquid interface, or bubble detachment from the interface were observed during the low gravity experiments. During the SPAR 3 experiment, a unique bubble motion-fluid flow event occurred in one specimen: a large bubble moved downward and caused some circulation of the melt. The gas bubbles that were trapped by the solid in commercial purity material formed voids that had a cyclindrical shape in SPAR 3, in contrast to the spherical shape that had been observed in SPAR 1. These shapes were not influenced by the gravity level, but were dependent upon the initial temperature gradient. In higher purity material the shape of the voids changed from cylindrical in one-g to spherical in low-g.
Experiments were performed to study the effect of a low-gravity environment on the columnar-to-equiaxed transition (CET) during polycrystalline solidification. Solutions of H2O-30 wt% NH4Cl and H2O-37 wt% NH4Cl were solidified in semicylindrical molds with radial heat extraction. Both solutions were quenched from the same soak temperature (90 C); the respective superheat temperatures were, therefore, approximately 57 and 23 C. The lower superheat resulted in a completely columnar structure, and the higher superheat resulted in a 1/3 columnar - 2/3 equiaxed microstructure; these results were independent of the relationship between heat flow direction and gravity. Grain multiplication mechanisms observed were showering, thermal inversion driven convection cells, and compositionally induced density inversion driven convection cells.
The behavior of bubbles at a dendritic solidification interface was studied during the coasting phase of a sounding rocket flight. Sequential photographs of the gradient freeze experiment showed nucleation, growth and coalescence of bubbles at the moving interface during both the low-gravity and one-gravity tests. In the one-gravity test the bubbles were observed to detach from the interface and float to the top of the melt. However, in the low-gravity tests no bubble detachment from the interface or steady state bubble motion occurred and large voids were grown into the crystal. These observations are discussed in terms of the current theory of thermal migration of bubbles and in terms of their implications on the space processing of metals.
Specimens of gas saturated carbon tetrabromide were directionally solidified in a transparent furnace using a gradient freeze technique. The original temperature gradient was 5 C/cm and the cooling rate was 40 C/h. Progress of the experiment was monitored photographically. Gas bubbles were generated at the advancing solidification front in each of the three specimens. The gas bubbles were observed to increase in size, coalesce, and eventually be grown into the solid specimen under low gravity conditions. No bubble detachment from the interface was observed. Identical specimens processed in the laboratory showed bubble nucleation, bubble growth, and eventual bubble detachment due to buoyancy forces. Examination of the specimens showed a significantly greater void content in the low gravity processed samples. The grain size was observed to be finer in the low gravity processed samples.
The containerless solidification of several pure metals and metallic alloys was studied in a low gravity environment. The tests were performed in the MSFC 4.2 s drop tower using a rapid wire melting apparatus designed and built for this purpose. Pure iron and nickel, and alloys of iron-nickel, iron-carbon, nickel-aluminum and tungsten-rhenium were all melted and solidified at a gravity level of approximately 100.000/-4 g. Interpretation of the results has led to an appreciation of the factors controlling the successful execution of this drop test experiment and to a delineation of the limits of applicability of the apparatus. Preliminary metallurgical evaluations are presented of the overall shapes, lattice parameters, surface microstructure,, cross-sectional microstructures, solidification and transformation sequences, evaporative segregation, and localized solute redistribution observed in the low-gravity specimens. The effects of low gravity on metallic solidification are discussed with particular emphasis on observations of spontaneous undercooling and evaporative segregation in uncontained melts.