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Several rules to guide choice of materials, and methods of welding, electroplating, and heat treatment will provide a method for minimizing failures in storage tanks and related hardware. Failures are caused by high-pressure hydrogen effects, the formation of hydrides in titanium, and hydrogen absorption through various metals processing techniques.
The feasibility of reducing the gas permeability rate of Mylar and Kapton films without drastically effecting their flexibility characteristics at cryogenic temperatures was considered. This feasibility was established using a concept of diffusion bonding two layers of metallized films together forming a film-metal-film sandwich laminate. The permeability of kapton film to gaseous helium was reduced from a nominal ten = to the minus 9 power cc-mm/sq cm sec. cm Hg to ten to the minus 13 power cc-mm/ sq cm - sec. cm Hg with some values as low as ten to the minus 15 power cc - mm/sq cm m-sec - cm Hg being obtained. Similar reductions occurred in the liquid hydrogen permeability at -252 C. In the course of the program the permeability, flexibility and bond strength of plain, metalized and diffusion bond film were determined at +25 C, -195 C and -252 C. The cryogenic flexibility of Kapton film was reduced slightly due to the metallization process but no additional loss in flexibility resulted from the diffusion bonding process.
The major objectives of the Skylab project are to examine the medical aspects of what happens to man in long duration space flight, to make long-duration studies of the active and the quiet sun, and to gather data in the study of the ocean and the land masses of the earth. Corollary experiments use either the fact that they are to be performed in a complete vacuum, or the fact that the stars and the ultraviolet can be much more extensively studied. Some experiments in metal processing will make use of the zero force field.
Effective fabrication methods for aluminum/boron and aluminum/graphite composites have been investigated. Drawing and rolling were found to be adaptable to Al/B fabrication. Although graphite composites are not amenable to standard metal processing methods, it may be possible to reduce fabrication costs of Al/C through electron-beam heating.
Method predicts absorption of hydrogen into metals. Process can aid designers of hydrogen-storage facilities for electric power plants.
Polyimide dielectric materials were acquired for comparative and evaluative studies in double layer metal processes. Preliminary experiments were performed. Also, the literature indicates that sputtered aluminum films may be successfully patterned using the left-off technique provided the substrate temperature remains low and the argon pressure in the chamber is relatively high at the time of sputtering. Vendors associated with dry processing equipment are identified. A literature search relative to future trends in VLSI fabrication techniques is described.
In large area, low cost solar cells of any type, the contact and grid structure metallization is an important factor which has an effect on the efficiency of the solar cell and its reliability. The present investigation is concerned with aspects of solar cell efficiency. An optimized metallization design leads to minimum total power loss, which is related to a simultaneous minimization of ohmic voltage drops and of shading of the front surface of the cell by the overlaid metal. The requirements regarding the design for a low-loss metallization pattern for the front surface of large area solar cells are represented by a set of design rules listed in a table. The total shading and voltage drop on such cells can be held to about 5%. However, not every metallization process is suited for meeting the requirements of the low-cost design. The low losses can be achieved only by use of several bus lines containing a bulk conductor, such as a wire.
Toroidal induction heater is key element in rapid bonding technique. Rapid adhesive bonding equipment features toroid induction heater for quick bonding of composites and metals. Process avoids damaging composites that cannot withstand high temperatures for long time intervals. Process scaled up for production. Technique suited to bonding of end tabs onto material test specimens.
An accurate study and evaluation of dielectric thin films is conducted in order to find the material or combination of materials which would optimize NASA'S double layer metal process. Emphasis is placed on polyimide dielectrics because of their reported outstanding dielectric characteristics (including electrical, chemical, thermal, and mechanical) and ease of processing, as well as their rapid acceptance by the semiconductor industry.
Carbonization of fibers at high temperatures improves strength and erosion resistance. Cotton linters tested as replacement for asbestos filler currently used in rubber insulation in solid rocket motors. Cotton-filled rubber insulation has industrial uses; in some kinds of chemical- or metal-processing equipment, hoses, and protective clothing.
Corrosion evaluation studies were conducted on 4130 alloy steel samples coated with electrodeposited zinc-nickel and samples coated with electrodeposited cadmium. The zinc nickel was deposited by the selection electrochemical metallizing process. These coated samples were exposed to a 5-percent salt fog environment at 35 plus or minus 2 C for a period ranging from 96 to 240 hours. An evaluation of the effect of dichromate coatings on the performance of each plating was conducted. The protection afforded by platings with a dichromate seal was compared to platings without the seal. During the later stages of testing, deposit adhesion and the potential for hydrogen entrapment were also evaluated.
Reagentless ultraviolet absorption spectrometry (UVAS) and Liquid Atomic Emission Spectrometry (LAES) represent new forms of spectrometry with extensive potential in both space and commercial applications. Originally developed under KSC sponsorship for monitoring nutrient solutions for the Controlled Ecological Life Support System (CELSS), both UVAS and LAES have extensive analytical capabilities for both organic and inorganic chemical compounds. Both forms of instrumentation involve the use of remote fiber optic probes and real-time measurements for on-line process monitoring. Commercial applications exist primarily in environmental analysis and for process control in the chemical, pulp and paper, food processing, metal plating, and water/wastewater treatment industries.
Sandia National Laboratories has identified technology transfer to U.S. industry as a laboratory mission which complements our national security mission and as a key component of the Laboratory's future. A number of technology transfer mechanisms - such as CRADA's, licenses, work-for-others, and consortia - are identified and specific examples are given. Sandia's experience with the Specialty Metals Processing Consortium is highlighted with a focus on the elements which have made it successful. A brief discussion of Sandia's potential interactions with NASA under the Space Exploration Initiative was included as an example of laboratory-to-NASA technology transfer. Viewgraphs are provided.
This report documents the completion of, and improvements made to, the software developed for automated data acquisition and automated modeling and control development on the Texas Micro rackmounted PC's. This research was initiated because a need was identified by the Metal Processing Branch of NASA Marshall Space Flight Center for a mobile data acquisition and data analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC based system was chosen. The Welding Measurement System (WMS), is a dedicated instrument strickly for use of data acquisition and data analysis. In addition to the data acquisition functions described in this thesis, WMS also supports many functions associated with process control. The hardware and software requirements for an automated acquisition system for welding process parameters, welding equipment checkout, and welding process modeling were determined in 1992. From these recommendations, NASA purchased the necessary hardware and software. The new welding acquisition system is designed to collect welding parameter data and perform analysis to determine the voltage versus current arc-length relationship for VPPA welding. Once the results of this analysis are obtained, they can then be used to develop a RAIL function to control welding startup and shutdown without torch crashing.
Aluminum-Lithium is a modern material that NASA MSFC is evaluating as an option for the aluminum alloys and other aerospace metals presently in use. The importance of aluminum-lithium is in it's superior weight to strength characteristics. However, aluminum-lithium has produced many challenges in regards to manufacturing and maintenance. The solution to these problems are vital to the future uses of the shuttle for delivering larger payloads into earth orbit and are equally important to future commercial applications of aluminum-lithium. The Metals Processes Branch at MSFC is conducting extensive tests on aluminum-lithium which includes the collection of large amounts of data. This report discusses the automation and data acquisition for two processes: the initial weld and the repair. The new approach reduces the time required to collect the data, increases the accuracy of the data, and eliminates several types of human errors during data collection and entry. The same material properties that enhance the weight to strength characteristics of aluminum-lithium contribute to the problems with cracks occurring during welding, especially during the repair/rework process. The repairs are required to remove flaws or defects discovered in the initial weld, either discovered by x-ray, visual inspection, or some other type of nondestructive evaluation. It has been observed that cracks typically appear as a result of or beyond the second repair. MSFC scientists have determined that residual mechanical stress introduced by the welding process is a primary cause of the cracking. Two obvious solutions are to either prevent or minimize the stress introduced during the welding process, or remove or reduce the stress after the welding process and MSFC is investigating both of these.
Quench Module Insert is a directional solidification furnace, which will fly in the Materials Science Research Facility. The QMI provides high thermal gradient and quench capabilities for processing metals and alloys in microgravity. This paper will describe the capabilities and present of on-going analysis and development testing.
The Quench Module Insert is a directional solidification furnace that will operate in the Materials Science Research Rack (MSRR) on the International Space Station. It will provide high thermal gradient and quench capabilities for processing metals and alloys in microgravity. Numerical analyses and breadboard testing conducted to date show that the QMI can produce an axial temperature gradient approaching 150 C per centimeter in a 1 centimeter diameter aluminum sample with a maximum molten sample temperature of 1100 C. Breadboard testing and analysis have also shown that the quench capabilities of the furnace are sufficient to rapidly solidify at least a 5mm axial portion of a 1 centimeter diameter molten aluminum sample in significantly less than the required 2 seconds and prevent significant backmelt. This paper presents the furnace requirements and capabilities and a status of the associated development testing and analyses.
The session "Chondrules: The Never-Ending Story" included the following reports:Dust Size Distribution in Solar Nebula Inferred from Shock-Wave Heating Model for Chondrule Formation; Collisional Destruction of Chondrules in Shock Waves and Inferred Dust to Gas Mass Ratio; Evaporation and Accompanying Isotopic Fractionation of Sulfur from Fe-S Melt During Shock Wave Heating ; Evaporation During Chondrule Formation, Recondensation as Fine Particles, and the Condensation of S and Other Volatile Elements; Fe Isotopes and the Formation of Chondrules; Pristine and Processed Metal in CR Chondrites: Condensation in the Solar Nebula and Partial Reequilibration During Chondrule Formation; Variation of the Condensation Path of Supercooled Silicate Melt; Volatile and Moderately Volatile Trace Element Composition of Chondrules and Matrix from CM Chondrites: Implications for Chondrule Formation; Opaque Mineral Assemblages at Chondrule Boundaries in the Vigarano CV Chondrite: Evidence for Gas-Solid Reactions Following Chondrule Formation; Forsterite and Olivine in Sahara-97210 (LL3.2) and Chainpur (LL3.4) Chondrules: Compositional Evolution and the Influence of Melting; The Vaguries of Pyroxene Nucleation and the Resulting Chondrule Textures; Contemporaneous Formation of Chondrules in the Al-26-Mg-26 System for Ordinary and CO Chondrites; and Al-Mg Isotopic Systematics in Ferromagnesian Chondrules from the Unequilibrated Ordinary Chondrite.