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NASA NTRS1990

Effect of convection on the microstructure of a lamellar eutectic growing with a stepped interface

A two dimensional model developed to study the influence of convective flow on the concentration field ahead of a growing lamellar eutectic is described when one phase projects out into the melt creating a stepped interface. The two dimensional convective flow field, which is periodic in the horizontal direction, was computed numerically using the software FLUENT. The velocity field generated due to the flow of melt over the steps was then incorporated into a finite difference scheme employed to solve the concentration field. The average interfacial composition was calculated and converted to lamellar spacing using the Jackson and Hunt minimum supercooling criterion. It was found that a stepped interface is more sensitive to convection than a planar interface.

Seth, Jayshree↗

NASA NTRS1991

Effect of convection on the microstructure of a lamellar eutectic growing with a stepped interface

Seth, Jayshree↗

NASA NTRS1989

Thermocapillary convection in zone-melting crystal growth - An open-boat physical simulation

Thermocapillary convection in a molten zone of NaNO3 contained in a boat with a free horizontal surface, that is heated from above by a centered wire heater, was studied to simulate flow in zone-melting crystal growth. Using a laser-light-cut technique and fine SiO powder as a tracer, convection in the melt zone was visualized in two different cases. In the first case, the entire melt surface was free, while in the second the melt surface was free only in the immediate vicinity of one vertical wall and was covered elsewhere, this wall being to simulate the melt/crystal interface during crystal growth. It was observed that thermocapillary convection near this wall prevailed in the first case, but was reduced significantly in the second. Since thermocapillary rather than natural convection dominated in the melt, the effect of the partial covering of the melt surface on thermocapillary convection in the melt observed in this study is expected to be similar under microgravity.

Kim, Y. J.↗

NASA NTRS1999

Control of Meridional Flow in Circular Cylinders by a Travelling Axial Magnetic Field

Convective flow in a Bridgman or float zone configuration significantly affects the interface shape and segregation phenomena. While the primary causative factor for this flow is buoyancy induced convection in an enclosed Bridgman melt, the presence of a free surface gives rise to surface tension driven flows in the floating zone processing of melts. It is of interest to curtail these flows in order to realize near quiescent growth conditions that have shown to result in crystals with good longitudinal and radial homogeneity and thereby of better overall quality. While buoyancy effects can be reduced by careful processing in a low gravity (space) environment, the reduction of Marangoni flows due to surface tension variations is not that straight forward. Attempts have been made with some limited success with the use of external fields to affect the melt thermo-fluid behavior. The use of a static magnetic field that reduces convective contamination through the effects of a non-intrusively induced, dissipative Lorentz force in an electrically conducting melt is one such approach. Experiments have shown that axial fields of the order of 5 Tesla can significantly eliminate convection and yield close to diffusion limited crystal growth conditions. The generation and use of such high magnetic fields require substantial hardware and incur significant costs for its operation. Lately, the use of rotating magnetic fields has been tested in semiconductor crystal growth. The method is fairly well known and commonly used in metal processing but its adaptation to crystal growth of semiconductors is fairly recent. The elegance of the technique rests in its low power requirement (typically 10-20 milli-Tesla at 50-400 Hz) and its efficacy in curtailing deleterious temperature fluctuations in the melt. A rotating magnetic field imposes a rotational force and thereby induces a circulation within the melt that tends to dominate other sporadic convective effects. Thus a known low level of convective flow is introduced into the system. A new novel variation of the Lorentz force mechanism is proposed and investigated in this study. Since one of the desired process conditions in melt crystal growth is the minimization of convective effects, this investigation examines the use of an external field of magnetic origin to counteract existing convective flow within the melt. This is accomplished by utilizing a running or traveling axial magnetic wave in the system. The concept is similar to the use of vibrational means in order to induce streaming flows that oppose buoyant or surface tension driven convection in the system. The rotation direction as well as the magnitude (strength) of this circulation can be easily controlled by external inputs thus affording a direct means of controlling the developing shape of the crystallizing front (interface). The theoretical model of this technique is fully developed and presented in this paper. Results from the solution of the developed governing equations and boundary conditions are also presented. An experimental demonstration of the concept is presented through the suppression of natural convective flow in a mercury column. Implications to crystal growth systems will be fully explored in the final manuscript.

Mazuruk, K.↗

NASA NTRS1999

Melt Stabilization of PbSnTe in a Magnetic Field

Both the experimental observation and numerical simulation indicate that the Bridgman growth of PbSnTe under the microgravity environment in space is still greatly influenced by buoyancy-induced convection. The application of a magnetic field during the semiconductor growth can dampen the convective flow in the metal-like melt. However, for Bridgman growth of PbSnTe on earth (with either vertical or horizontal configuration), both experimental observation and numerical modeling suggest that even with a strong magnetic furnace (5-Tesla constant axial magnetic field), the convective flow in the melt still cannot be sufficiently suppressed to reach the diffusion-controlled level. In order to completely dampen the buoyancy-induced convection on earth, estimates based on scaling analysis indicate that for common experimental conditions, an extremely high magnetic field is required, far beyond the capacity of the experimental apparatus currently available. Therefore, it is proposed that only the combination of microgravity environment and magnetic damping will produce the desired diffusion-controlled growth state for this particular material. The primary objectives of this study are to provide a quantitative understanding of the complex transport phenomena during solidification of non-dilute binarys, to furnish a numerical tool for furnace design and growth condition optimization, to provide estimates of the required magnetic field strength for low gravity growth, and to assess the role of magnetic damping for space and earth control of the double-diffusive convection. As an integral part of a NASA research program, our numerical simulation supports both the flight and ground-based experiments in an effort to bring together a complete picture of the complex physical phenomena involved in the crystal growth process. For Bridgman growth of PbSnTe under microgravity (with both vertical and horizontal configurations), the simulations suggest that a moderate axial magnetic field of only a few kilo-Gauss in strength could effectively eliminate buoyancy-induced convection in the melt and control solute segregation. Therefore, this work confirms the idea that the combination of microgravity environment and the magnetic damping will indeed be sufficient to produce the desired diffusion-controlled growth state for PbSnTe.

Fripp, Archibald L.↗

NASA NTRS2003

Transient Torque Method: A Fast and Non-Intrusive Technique to Simultaneously Determine Viscosity and Electrical Conductivity of Semiconducting and Metallic Melts

A transient torque method was developed to rapidly and simultaneously determine the viscosity and electrical conductivity of semiconducting or metallic melts. The experimental setup is similar to that for the oscillation cup technique. The melt sample is sealed inside a fused silica ampoule, and the ampoule is suspended by a long quartz fiber to form a torsional oscillation system. A rotating magnetic field is used to induce a rotating flow in the conductive melt, which causes the ampoule to rotate along its axis. A sensitive angular detector is used to measure the deflection angle of the ampoule. Based on the transient behavior of the deflection angle as the rotating magnetic field is applied, the electrical conductivity and viscosity of the melt can be obtained simultaneously by numerically fitting the data to a set of governing equations. The transient torque viscometer was applied successfully to measure the viscosity and electrical conductivity of high purity mercury at 53.4 C. The results were in excellent agreement with the published data. The main advantage of the technique is that the measurement can be completed in one or two minutes, as opposed to the one or two-hour measurement time required by the oscillation cup technique. The method is non-intrusive; capable of rapid measurement of the viscosity of toxic, high vapor pressure melts at elevated temperatures. In addition, the transient torque viscometer can also be operated as an oscillation cup viscometer if desired.

Li, C.↗

NASA NTRS2004

Transient Torque Method: A Fast and Nonintrusive Technique to Simultaneously Determine Viscosity and Electrical Conductivity of Semiconducting and Metallic Melts

A transient torque method was developed to rapidly and simultaneously determine the viscosity and electrical conductivity of liquid metals and molten semiconductors. The experimental setup of the transient torque method is similar to that of the oscillation cup method. The melt sample is sealed inside a fused silica ampoule, and the ampoule is suspended by a long quartz fiber to form a torsional oscillation system. A rotating magnetic field is used to induce a rotating flow in the conductive melt, which causes the ampoule to rotate around its vertical axis. A sensitive angular detector is used to measure the deflection angle of the ampoule. Based on the transient behavior of the deflection angle as the rotating magnetic field is applied, the electrical conductivity and viscosity of the melt can be obtained simultaneously by numerically fitting the data to a set of governing equations. The transient torque viscometer was applied successfully to measure the viscosity and electrical conductivity of high purity mercury at 53.4 C. The results were in excellent agreement with published data. The method is nonintrusive; capable of rapid measurement of the viscosity of toxic, high vapor pressure melts at elevated temperatures. In addition, the transient torque viscometer can also be operated as an oscillation cup viscometer to measure just the viscosity of the melt or as a rotating magnetic field method to determine the electrical conductivity of a melt or a solid if desired.

Li, C.↗

NASA NTRS1992

Venusian sinuous rilles

After a preliminary assessment of venusian channels, it now seems to be clear that the channels have distinctive classes, which imply a wide range of formation parameters and formation mechanisms. They include outflow channels mainly formed by mechanical erosion from very high discharge flow, and canali-type channels requiring either constructional process or mechanical erosion by rather exotic low-viscosity lava such as carbonatite or sulfur. Here we focus on venusian sinuous rilles. Venusian sinuous rilles are generally simple, and originate from a collapsed source. They are shallow and narrow downstream. The venusian sinuous rilles are distinct from canali-type channels, which exhibit almost constant morphologies throughout their entire length, and from outflow channels, which are characterized by wide anastomosing reaches. The lunar sinuous rilles could have been formed initially as constructional channels. However, incision was caused by the long flow duration and high temperatures of eruption, along with relatively large discharge rates, possibly assisted by a low viscosity of the channel-forming lava. Channel narrowing and levee formation suggest relatively fast cooling. The venusian channels could have had a similar sequence of formation including rapid cooling. Assuming the substrate is typical tholeiitic lava, the flowing lavas' temperatures have to be higher than the melting temperature of the substrate. The flow should have a low viscosity to cause turbulence and keep a high Reynolds number to sustain efficient thermal erosion. Determining eruption conditions also provide insights to estimate lava composition. Assuming a channel is formed mostly by thermal erosion, the channel's length and longitudinal profile are functions of lava properties. The depth profiles of the channel are measured by radar foreshortening methods and stereo images. Eruption conditions of channel forming lava can be estimated by the methods developed by Hulme.

Komatsu, G.↗

NASA NTRS2004

Semiconductor Crystal Growth in Static and Rotating Magnetic fields

Magnetic fields have been applied during the growth of bulk semiconductor crystals to control the convective flow behavior of the melt. A static magnetic field established Lorentz forces which tend to reduce the convective intensity in the melt. At sufficiently high magnetic field strengths, a boundary layer is established ahead of the solid-liquid interface where mass transport is dominated by diffusion. This can have a significant effect on segregation behavior and can eliminate striations in grown crystals resulting from convective instabilities. Experiments on dilute (Ge:Ga) and solid solution (Ge-Si) semiconductor systems show a transition from a completely mixed convective state to a diffusion-controlled state between 0 and 5 Tesla. In HgCdTe, radial segregation approached the diffusion limited regime and the curvature of the solid-liquid interface was reduced by a factor of 3 during growth in magnetic fields in excess of 0.5 Tesla. Convection can also be controlled during growth at reduced gravitational levels. However, the direction of the residual steady-state acceleration vector can compromise this effect if it cannot be controlled. A magnetic field in reduced gravity can suppress disturbances caused by residual transverse accelerations and by random non-steady accelerations. Indeed, a joint program between NASA and the NHMFL resulted in the construction of a prototype spaceflight magnet for crystal growth applications. An alternative to the suppression of convection by static magnetic fields and reduced gravity is the imposition of controlled steady flow generated by rotating magnetic fields (RMF)'s. The potential benefits of an RMF include homogenization of the melt temperature and concentration distribution, and control of the solid-liquid interface shape. Adjusting the strength and frequency of the applied magnetic field allows tailoring of the resultant flow field. A limitation of RMF's is that they introduce deleterious instabilities above a critical magnetic field value. Growth conditions in which static magnetic fields rotational magnetic fields, and reduced gravitational levels can have a beneficial role will be described.

Volz, Martin↗

NASA NTRS1985

MCZ: Striations in CZ silicon crystals grown under various axial magnetic field strengths

Suppression of fluid flow instabilities in the melt by the axial magnetic field in Czochralski silicon crystal growth (AMCZ) is investigated precisely by a high-sensitivity striation etching in conjunction with temperature measurements. The magnetic strength (B) was varied up to 4.0 kG, incremented in 0.5 kG/5 cm crystal length. The convection flow was substantially suppressed at B 1.0 kG. A low oxygen level of 2-3 ppma and a high resistivity of 400 ohm-cm is achieved in the AMCZ silicon crystals at B 1.0 kG. Details of the striation formation as a function of B are presented. Computer simulation of the magnetohydrodynamics of the AMCZ silicon crystal growth are discussed briefly with regard to the solute, especially oxygen segregation at B=0, 1.0, and 2.0 kG. Earlier studies in the inverted Bridgman growth of InSb and Ge, which have established the cause and effect relationship between the convection in the melt and the striation formation as well as the suppression of the convections in the melt by transverse magnetic field are reviewed.

Kim, G. K. M.↗

NASA NTRS1990

Instability during directional solidification - Gravitational effects

After an elementary introduction to solidification, recent research that attempts to understand the interaction of fluid flow with a crystal-melt interface under gravitational influence using linear stability analysis is reviewed. Recent numerical calculations of fluid flow and interface morphology during alloy solidification are briefly discussed.

Coriell, S. R.↗

NASA NTRS1986

Analytical and numerical studies of the thermocapillary flow in a uniformly floating zone

The microgravity environment of an orbiting vehicle permits crystal growth experiments in the presence of greatly reduced buoyant convection in the liquid melt. Crystals grown in ground-based laboratories do not achieve their potential properties because of dopant variations caused by flow in the melt. The floating zone crystal growing system is widely used to produce crystals of silicon and other materials. However, in this system the temperature gradient on the free sidewall surface of the melt is the source of a thermocapillary flow which does not disappear in the low-gravity environment. The idea of using a uniform rotation of the floating zone system to confine the thermocapillary flow to the melt sidewall leaving the interior of the melt passive is examined. A cylinder of fluid with an axial temperature gradient imposed on the cylindrical sidewall is considered. A half zone and the linearized, axisymmetric flow in the absence of crystal growth is examined. Rotation is found to confine the linear thermocapillary flow. A simplified model is extended to a full zone and both linear and nonlinear thermocapillary flows are studied theoretically. Analytical and numerical methods are used for the linear flows and numerical methods for the nonlinear flows. It was found that the linear flows in the full zone have more complicated and thicker boundary layer structures than in the half zone, and that these flows are also confined by the rotation. However, for the simplified model considered and for realistic values for silicon, the thermocapillary flow is not linear. The fully nonlinear flow is strong and unsteady (a weak oscillation is present) and it penetrates the interior. Some non-rotating flow results are also presented. Since silicon as a large value of thermal conductivity, one would expect the temperature fields to be determined by conduction alone. This is true for the linear and weakly nonlinear flows, but for the stronger nonlinear flow the results show that temperature advection is also important. Uniform rotation may still be a means of confining the flow and the results obtained define the procedure to be used to examine this hypothesis.

Fowlis, W. W.↗

NASA NTRS2003

Pore Formation and Mobility Investigation (PFMI): Description and Initial Analysis of Experiments Conducted Aboard the International Space Station

Flow Visualization experiments on the controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The experimental samples were prepared on ground by filling glass tubes, 1 cm 1D and approximately 30 cm in length, with pure succinonitrile (SCN) under 450 millibar of nitrogen. Porosity in the samples arose from natural shrinkage, and in some cases by direct insertion of nitrogen bubbles, during solidification of the liquid SCN. The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus that is placed in the glovebox facility (GBX) aboard 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. During the experiments, the sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. The temperatures in the sample are monitored by six in situ thermocouples. Real time visualization of the controlled directional melt back shows bubbles of different sizes initiating at the melt interface and, upon dislodging from the melting solid, migrating at different speeds into the temperature field ahead of them, before coming to rest. The thermocapillary flow field set up in the melt, ahead of the interface, is dramatic in the context of the large bubbles, and plays a major role in dislodging the bubble. A preliminary analysis of the observed bubble formation and mobility during melt back and its implication to future microgravity experiments is presented and discussed.

Grugel, R. N.↗

NASA NTRS2003

Bubble Formation and Transport during Microgravity Materials Processing: Model Experiments on the International Space Station

Flow Visualization experiments on the controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The experimental samples were prepared on ground by filling glass tubes, 1 cm ID and approximately 30 cm in length, with pure succinonitrile (SCN) under 450 millibar of nitrogen. Porosity in the samples arose from natural shrinkage, and in some cases by direct insertion of nitrogen bubbles, during solidification of the liquid SCN. The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus that is placed in the glovebox facility (GBX) aboard 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. During the experiments, the sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. The temperatures in the sample are monitored by six in situ thermocouples. Real time visualization of the controlled directional melt back shows bubbles of different sizes initiating at the melt interface and, upon dislodging from the melting solid, migrating at different speeds into the temperature field ahead of them, before coming to rest. The thermocapillary flow field set up in the melt, ahead of the interface, is dramatic in the context of the large bubbles, and plays a major role in dislodging the bubble. A preliminary analysis of the observed bubble formation and mobility during melt back and its implication to future microgravity experiments is presented and discussed.

Grugel, R. N.↗

NASA NTRS2003

Bubble Formation and Transport during Microgravity Materials Processing: Model Experiments on the International Space Station

Flow Visualization experiments on the controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The experimental samples were prepared on ground by filling glass tubes, 1 cm ID and approximately 30 cm in length, with pure succinonitrile (SCN) under 450 millibar of nitrogen. Porosity in the samples arose from natural shrinkage, and in some cases by direct insertion of nitrogen bubbles, during solidification of the liquid SCN. The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus that is placed in the glovebox facility (GBX) aboard 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. During the experiments, the sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. The temperatures in the sample are monitored by six in situ thermocouples. Real time visualization of the controlled directional melt back shows bubbles of different sizes initiating at the melt interface and, upon dislodging from the melting solid, migrating at different speeds into the temperature field ahead of them, before coming to rest. The thermocapillary flow field set up in the melt, ahead of the interface, is dramatic in the context of the large bubbles, and plays a major role in dislodging the bubble. A preliminary analysis of the observed bubble formation and mobility during melt back and its implication to future microgravity experiments is presented and discussed.

Grugel, R. N.↗

NASA NTRS2003

Bubble Formation and Transport during Microgravity Materials Processing: Model Experiments on the Space Station

Flow Visualization experiments on the controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The experimental samples were prepared on ground by filling glass tubes, 1 cm ID and approximately 30 cm in length, with pure succinonitrile (SCN) under 450 millibar of nitrogen. Porosity in the samples arose from natural shrinkage, and in some cases by direct insertion of nitrogen bubbles, during solidification of the liquid SCN. The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus that is placed in the glovebox facility (GBX) aboard 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. During the experiments, the sample is first subjected to a unidirectional melt back, generally at 10 microns per second, with a constant temperature gradient ahead of the melting interface. The temperatures in the sample are monitored by six in situ thermocouples. Real time visualization of the controlled directional melt back shows bubbles of different sizes initiating at the melt interface and, upon dislodging from the melting solid, migrating at different speeds into the temperature field ahead of them, before coming to rest. The thermocapillary flow field set up in the melt, ahead of the interface, is dramatic in the context of the large bubbles, and plays a major role in dislodging the bubble. A preliminary analysis of the observed bubble formation and mobility during melt back and its implication to future microgravity experiments is presented and discussed.

Grugel, R. N.↗

NASA NTRS1984

Thermosolutal convection during directional solidification

During solidification of a binary alloy at constant velocity vertically upward, thermosolutal convection can occur if the solute rejected at the crystal-melt interface decreases the density of the melt. We assume that the crystal-melt interface remains planar and that the flow field is periodic in the horizontal direction. The time-dependent nonlinear differential equations for fluid flow, concentration, and temperature are solved numerically in two spatial dimensions for small Prandtl numbers and moderately large Schmidt numbers. For slow solidification velocities, the thermal field has an important stabilizing influence: near the onset of instability the flow is confined to the vicinity of the crystal-melt interface. Further, for slow velocities, as the concentration increases, the horizontal wavelength of the flow decreases rapidly - a phenomenon also indicated by linear stability analysis. The lateral inhomogeneity in solute concentration due to convection is obtained from the calculations. For a narrow range of solutal Rayleigh numbers and wavelengths, the flow is periodic in time.

Mcfadden, G. B.↗

NASA NTRS1990

The effects of g-jitter and surface tension induced convection on float zones

The effects of g-jitter on nonencapsulated and encapsulated liquid bridges were investigated numerically, using fluid characteristics and parameters from three fluid systems: a silicone oil bridge, a methanol bridge, and a silicon melt. Results showed that complex flow patterns can arise in g-jitter environment which significantly modify the heat-transfer characteristics of the system. It was found that the nonencapsulated liquid bridges and float zone melts were dominated by surface-tension driven convection, with very little impact on the flows by residual and g-jitter accelerations. Zone encapsulation resulted in a sizeable drop in the maximum fluid velocities. The g-jitter computations on the encapsulated float zones resulted in significant augmentation of the maximum velocities and heat transfer, with the silicon melt being the least sensitive to g-jitter acceleration.

Ramachandran, N.↗