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At least 235 records · Page 13

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NASA NTRS1994

The behavior of unsteady thermocapillary flows

The thermocapillary-driven flow of a liquid in a shallow slot provides a simple model to explore the effects of free-surface deflection and end walls on the stability of the flow. Such an investigation may be useful in understanding the complex flow seen in processes such as the float-zone refining of single crystals. A linear stability analysis of the viscously-dominated slot flow indicates stable basic states to both tow- and three-dimensional infinitesimal disturbances for capillary numbers below 43.3. Above this capillary number steady solutions do not exist. We also discuss current work involving the development of an inertially-dominated slot-flow model using singular perturbation methods. If these flows are unstable, inertial effects would be the only possible cause of the instability.

Vrane, David R.↗

NASA NTRS1994

Influence of flow on interface shape stability in low gravity

The objectives are to: (1) Understand the influence in low gravity of flow on interface shape. For example, document and control the influence of axial flow on the Plateau-Rayleigh instability of a liquid bridge; and (2) Extend the ground-based density-matching technique of low gravity simulation to situations with flow; that is, develop Plateau chamber experiments for which flow can be controlled. Containerless containment of liquid by surface tension has broad importance in low gravity. For space vehicles, the behavior of liquid/gas interfaces is crucial to successful liquid management systems. In microgravity science, free interfaces are exploited in various applications. Examples include float-zone crystal growth, phase separation near the critical point of liquid mixtures (spinoidal decomposition) and quenching of miscibility gap molten metal alloys. In some cases, it is desired to stabilize the capillary instability while in others it is desired to induce capillary breakup. In all cases, understanding the stability of interface shape in the presence of liquid motion is central.

Steen, Paul H.↗

NASA NTRS1996

Critical Velocities in Open Capillary Flow

This paper describes the proposed research program on open capillary flow and the preliminary work performed theoretically and in drop tower experiments. The work focuses on the fundamental physical understanding of the flow through capillary bound geometries, where the circumference of the cross section of the flow path contains free surfaces. Examples for such a flow configuration are capillary vanes in surface tension tanks, flow along edges and corners and flow through liquid bridges. The geometries may be classified by their cross section areas, wetted circumferences and the radii of curvature of the free surfaces. In the streaming float zone the flow path is bound by a free surface only. The ribbon vane is a model for vane types used in surface tension tanks, where a structure in proximity to the tank wall forms a capillary gap. A groove is used in heat pipes for the transportation of the condensed working fluid to the heat source and a wedge may occur in a spaceborne experiment where fluid has to be transported by the means of surface tension. The research objectives are the determination of the maximum volume flux, the observation of the free surfaces and the liquid flow inside the flow path as well as the evaluation of the limiting capillary wave speed. The restriction of the maximum volume flux is due to convective forces (flow velocity exceeding the capillary wave speed) and/or viscous forces, i.e. the viscous head loss along the flow path must be compensated by the capillary pressure due to the curved free surface. Exceeding the maximum volume flux leads to the choking of the flow path, thus the free surface collapses and.gas ingestion occurs at the outlet. The means are ground-based experimental work with plateau tanks and in a drop tower, a sounding rocket flight, and theoretical analysis with integral balances as well as full three dimensional CFD solutions for flow with free surfaces.

Dreyer, Michael↗

NASA NTRS1996

Towards and FVE-FAC Method for Determining Thermocapillary Effects on Weld Pool Shape

Several practical materials processes, e.g., welding, float-zone purification, and Czochralski crystal growth, involve a pool of molten metal with a free surface, with strong temperature gradients along the surface. In some cases, the resulting thermocapillary flow is vigorous enough to convect heat toward the edges of the pool, increasing the driving force in a sort of positive feedback. In this work we examine this mechanism and its effect on the solid-liquid interface through a model problem: a half space of pure substance with concentrated axisymmetric surface heating, where surface tension is strong enough to keep the liquid free surface flat. The numerical method proposed for this problem utilizes a finite volume element (FVE) discretization in cylindrical coordinates. Because of the axisymmetric nature of the model problem, the control volumes used are torroidal prisms, formed by taking a polygonal cross-section in the (r, z) plane and sweeping it completely around the z-axis. Conservation of energy (in the solid), and conservation of energy, momentum, and mass (in the liquid) are enforced globally by integrating these quantities and enforcing conservation over each control volume. Judicious application of the Divergence Theorem and Stokes' Theorem, combined with a Crank-Nicolson time-stepping scheme leads to an implicit algebraic system to be solved at each time step. It is known that near the boundary of the pool, that is, near the solid-liquid interface, the full conduction-convection solution will require extremely fine length scales to resolve the physical behavior of the system. Furthermore, this boundary moves as a function of time. Accordingly, we develop the foundation of an adaptive refinement scheme based on the principles of Fast Adaptive Composite Grid methods (FAC). Implementation of the method and numerical results will appear in a later report.

Canright, David↗

NASA NTRS1997

The Behavior of Unsteady Thermocapillary Flows

We have found that it is possible to have steady thermocapillary flows in any of these three systems provided the liquid layer is not too thin or the surface tension is not too small. If these conditions are not met, then no steady solutions are possible and the film thins and approaches a condition of rupture near the hot end. Future work on these problems will include the effect of liquid inertia in the calculations for the cylindrical cavity. The stabilization effect of inertia may offset the destabilization effect inherent in the cylindrical geometry and result in a stable film flow on the cylinder. This type of behavior could be very significant in terms of understanding the stability of thermocapillary flow in liquid bridges and in the float-zone crystal growth process.

Smith, Marc K.↗

NASA NTRS1998

Laser Heated Oxide Fiber Growth Using Melt Modulation Technique

As a reinforcement for structural composites, single crystal alumina fibers offer low density, high modulus, and high creep resistance. In this study, the laser heated float zone approach was employed to grow c-axis Al2O3 continuous fibers of high purity and high strength. A new melt modulation technique, laser scanning, avoids the formation of surface induced ripples and allows the growth of 50 micro-m diameter sapphire fibers with strengths (approx. 7 GPa) significantly greater than either commercially available fibers grown by the edge-defined film growth process (approx. 2-3 GPa) or laboratory fibers grown by stationary laser heating (approx. 5 GPa). The present work suggests that surface striations are the predominant defects controlling the tensile strength of laser-scanned fibers at room temperature. Several possible mechanisms for inducing surface striations are systematically discussed for several oxide fiber compositions.

Sayir, Ali↗

NASA NTRS1997

Flow and Crystallization in Two-Layer Liquid Systems with and without a Magnetic Field

Flow, heat and mass transfer in a two-layer liquid system is investigated when the layers are subjected to a static magnetic field. The physical system consists of two immiscible liquids in a layer configuration with a free surface and an interfacial layer simulating two crystal growth configurations, namely, floating zone and horizontal zone melting. Mass transfer effects due to crystallization of one of the layers is also considered. The resulting flows are categorized into three types depending on: (a) the dominance of the free surface effect top layer, (b) a balance between the thermocapillary effect on the free surface and the interface effect between the two layers, or (c) the dominance of interfacial effects, in determining the system thermo-fluid characteristics. The use of an additional liquid layer atop the crystallizing layer leads to a reduction of the radial dopant inhomogeneity in comparison to the one-layer case. The effect an externally imposed magnetic field on dopant distribution in this two-layer configuration is rather ambiguous and depends on its direction and intensity resulting in the necessity of optimizing the applied magnetic field for a specific situation. In case of electrically non-conducting melts, the calculations show that some measure of flow control can be achieved by using an electrically conducting encapsulant layer of the desired thickness.

Feonychev, Alexander I.↗

NASA NTRS1999

Identification of Gravity-Related Effects on Crystal Growth From Melts With an Immiscibility Gap

This work involves an experimental-numerical approach to study the effects of natural and Marangoni convections on solidification of single crystals from a silicate melt with a liquid-liquid immiscibility gap. Industrial use of crystals grown from silicate melts is becoming increasingly important in electronic, optical, and high temperature structural applications. Even the simplest silicate systems like Al203-SiO2 have had, and will continue to have, a significant role in the development of traditional and advanced ceramics. A unique feature of crystals grown from the silicate systems is their outstanding linear electro-optic properties. They also exhibit exceptionally high optical rotativity. As a result, these crystals are attractive materials for dielectric, optical, and microwave applications. Experimental work in our laboratory has indicated that directional solidification of a single crystal mullite appears to be preceded by liquid-liquid phase separation in the melt. Disruption of the immiscible state results in crystallization of a two phase structure. There is also evidence that mixing in the melt caused by density-driven convection can significantly affect the stability of the immiscible liquid layers and result in poly-crystalline growth. On earth, the immiscible state has only been observed for small diameter crystals grown in float zone systems where natural convection is almost negligible. Therefore, it is anticipated that growth of large single crystals from silicate melts would benefit from microgravity conditions because of the reduction of the natural convective mixing. The main objective of this research is to determine the effects of transport processes on the phase separation in the melt during growth of a single crystal while addressing the following issues: (1) When do the immiscible layers form and are they real?; (2) What are the main physical characteristics of the immiscible liquids?; and (3) How mixing by natural or Marangoni convection affects the stability of the phase separated melt.

Kassemi, M.↗

NASA NTRS1998

The Role of Marangoni Convection for the FZ-Growth of Silicon

Fluctuations of the electrical resistivity due to inhomogeneous dopant distribution are still a serious problem for the industrial processing yield of doped silicon crystals. In the case of silicon floating-zone growth, the main sources of these inhomogeneities are time- dependent flows in the liquid phase during the growth process. Excluding radio frequency (RF) induced convection, buoyancy and thermocapillary (Marangoni) convection are the two natural reasons for fluid flow. Both originate from temperature/concentration gradients in the melt, buoyancy convection through thermal/concentrational volume expansion, and thermocapillary convection through the temperature/concentration dependence of the surface tension. To improve the properties of grown crystals, knowledge of the strength, the characteristic, and the relation of these two flow mechanisms is essential. By the use of microgravity, the effect and the strength of buoyancy (gravity dependent) and thermocapillary (gravity independent) convection can be separated and clarified. Applying magnetic fields, both convective modes can be influenced: fluid flow can either be damped (static magnetic fields) or overlaid by a regular flow regime (rotating magnetic fields). Two complementary approaches have been pursued: Silicon full zones (experiments on the German sounding rockets TEXUS 7, 12, 22, 29, and 36) with the maximum temperature at half of the zone height and silicon half zones (experiments on the Japanese sounding rockets TR-IA4 and 6) with the maximum temperature at the top of the melt. With the full zone arrangement, the intensity and the frequency of the dopant striations could be determined and the critical Marangoni number could be identified. The half zone configuration is suited to classify the flow pattern and to measure the amplitude and the frequency of temperature fluctuations in the melt by inserting thermocouples or temperature sensors into the melt. All experiments have been carried out in monoellipsoid mirror furnaces. Typical zone geometries are approx. 8 to 14 mm in diameter and height. The crystals grown under microgravity are compared to crystals grown in static axial magnetic fields (B<5 tesla) and in transversal rotating magnetic fields (B<7.5 mT / f=50 Hz). Experimental results are completed by 3D numerical simulations: the obtained temperature and concentration distribution in the melt confirm the damping effect of rotating magnetic fields and explain the change in the radial segregation under static magnetic fields.

Dold, P.↗

NASA NTRS1998

Magnetic Damping of Solid Solution Semiconductor Alloys

The objective of this study is to conduct the Earth-based research sufficient to successfully propose a flight experiment (1) to experimentally test the validity of the modeling predictions applicable to the magnetic damping of convective flows in conductive melts as this applies to the bulk growth of solid solution semiconducting materials in the reduced gravitational levels available in low Earth orbit and (2) to assess the effectiveness of steady magnetic fields in reducing the fluid flows occurring in these materials during space processing. To achieve the objectives of this investigation, we are carrying out a comprehensive program in the Bridgman and floating-zone configurations using the solid solution alloy system Ge-Si. This alloy system was chosen because it has been studied extensively in environments that have not simultaneously included both low gravity and an applied magnetic field. Also, all compositions have a high electrical conductivity, and the materials parameters permit high growth rates compared to many other commonly studied alloy semiconductors. An important supporting investigation is determining the role, if any, that thermoelectromagnetic convection (TEMC) plays during growth of these materials in a magnetic field. Some compositional anomalies observed by us in magnetic grown crystals can only be explained by TEMC; this has significant implications for the deployment of a Magnetic Damping Furnace in space. This effect will be especially important in solid solutions where the growth interface is, in general, neither isothermal nor isoconcentrational. It could be important in single melting point materials, also, if faceting takes place producing a non-isothermal interface.

Szofran, Frank R.↗

NASA NTRS1999

Control of Meridional Flow by a Non-Uniform Rotational Magnetic Field

The diffusive mass transfer of species during crystal growth in vertical ampoules is significantly affected by fluid flow in the liquid mother phase (melt). For electrically conductive melts, an elegant way of remotely inducing and controlling this flow is by utilizing a uniform rotational magnetic field (RMF) in the transverse direction. It induces an azimuthal flow which tends to homogenize the thermal and solutal fields. The rotating field also reduces the diffusion boundary layer, stabilizes temperature fluctuations, and promotes better overall crystal growth. For moderate strengths of the applied magnetic field (2-20 m Tesla) with frequencies of up to 400 Hz, the induced secondary meridional flow becomes significant. It typically consists of one roll at the bottom of the liquid column and a second roll (vortex) at the top. The flow along the centerline (ampoule axis) is directed from the growing solid (interface) towards the liquid (melt). In case of convex interfaces (e.g. in floating zone crystal growth) such flow behavior is beneficial since it suppresses diffusion at the center. However, for concave interfaces (e.g. vertical Bridgman crystal growth) such a flow tends to exacerbate the situation in making the interface shape more concave. It would be beneficial to have some control of this meridional flow- for example, a single recirculating cell with controllable direction and flow magnitude will make this technique even more attractive for crystal growth. Such flow control is a possibility if a non-uniform PNE field is utilized for this purpose. Although this idea has been proposed earlier, it has not been conclusively demonstrated so far. In this work, we derive the governing equations for the fluid dynamics for such a system and obtain solutions for a few important cases. Results from parallel experimental measurements of fluid flow in a mercury column subjected to non-uniform RMF will also be presented.

Mazuruk, Konstantin↗

NASA NTRS2000

Effects of End-Wall Vibration on Oscillatory Thermocapillary Flow

Our previous float zone experiments 1,2 with NaNO3 revealed that steady thermocapillary flow (TC flow) can be balanced/offset by the controlled surface streaming flow (CSS flow), induced by end-wall vibration. In the current experiments, we are examining the effects of surface streaming flow on steadying/stabilizing oscillatory thermocapillary flow. To this effect, we have set up a controlled NaNO3 half-zone experiment, where the processing parameters like zone dimensions and temperature gradients scan be easily varied to achieve oscillatory TC flow. In the present paper, we discuss the thermal signature of the TC flow, and how it is affected by imposition of CSS flow. The results will also include a comparison of the microstructure of a NaNO3- BaNO3 eutectic, processed under oscillatory TC conditions, with and without imposed CSS flow.

Bhowmick, J.↗

NASA NTRS2000

Crystallography of Alumina-YAG-Eutectic

Multiple descriptions of the alumina-YAG eutectic crystallography appear in the ceramic literature. The orientation between two phases in a eutectic system has direct impact on residual stress, morphology, microstructural stability, and high temperature mechanical properties. A study to demonstrate that the different crystallographic relationships can be correlated with different growth constraints was undertaken. Fibers produced by Laser-Heated Float Zone (LHFZ) and Edge-defined Film-fed Growth (EFG) were examined. A map of the orientation relationship between Al2O3 and Y3Al5O12 and their relationship to the fiber growth axis as a function of pull rate are presented. Regions in which a single orientation predominates are identified.

Farmer, Serene C.↗

NASA NTRS2000

Convection Induced by Traveling Magnetic Fields in Semiconductor Melts

Axisymmetric traveling magnetic fields (TMF) can be beneficial for crystal growth applications. such as the vertical Bridgman, float zone or traveling heater methods. TMF induces a basic flow in the form of a single roll. This type of flow can enhance mass and heat transfer to the growing crystal. More importantly, the TMF Lorentz body force induced in the system can counterbalance the buoyancy forces, so the resulting convection can be much smaller and even the direction of it can be changed. In this presentation, we display basic features of this novel technique. In particular, numerical calculations of the Lorentz force for arbitrary frequencies will be presented along with induced steady-state fluid flow profiles. Also, numerical modeling of the TMF counter-balancing natural convection in vertical Bridgman systems will be demonstrated.

Konstantin, Mazuruk↗

NASA NTRS1999

Stability of Shapes Held by Surface Tension and Subjected to Flow

Results of three problems are summarized in this contribution. Each involves the fundamental capillary instability of an interfacial bridge and is an extension of previous work. The first two problems concern equilibrium shapes of liquid bridges near the stability boundary corresponding to maximum length (Plateau-Rayleigh limit). For the first problem, a previously formulated nonlinear theory to account for imposed gravity and interfacial shear disturbances in an isothermal environment is quantitatively tested in experiment. For the second problem, the liquid bridge is subjected to a shear that models the effect of a thermocapillary flow generated by a ring heater in a liquid encapsulated float-zone configuration. In the absence of gravity, this symmetric perturbation can stabilize the bridge to lengths on the order of 30 percent beyond the Plateau-Rayleigh limit, which is on the order of heretofore unexplained Shuttle observations. The third problem considers the dynamics of collapse and pinchoff of a film bridge (no gravity), which happens in the absence of stabilization. Here, we summarize experimental efforts to measure the self-similar cone-and-crater structure predicted by a previous theory.

Chen, Yi-Ju↗

NASA NTRS2001

Some Novel Solidification Processing Techniques Being Investigated at MSFC: Their Extension for Study Aboard the ISS

The float-zone and the Bridgman techniques are two classical directional solidification processing methods that are used to improve materials properties. Unfortunately, buoyancy effects and gravity-driven convection due to unstable temperature and/or composition gradients still produce solidified products that exhibit segregation and, consequently, degraded properties. This presentation will briefly introduce how some novel processing applications can minimize detrimental gravitational effects and enhance microstructural uniformity. Discussion follows that to fully understand and model these procedures requires utilizing, in conjunction with a novel mixing technique, the facilities and quiescent microgravity environment available on the ISS.

Grugel, R. N.↗

NASA NTRS1997

Single Crystal Fibers of Yttria-Stabilized Cubic Zirconia with Ternary Oxide Additions

Single crystal fibers of yttria (Y2O3)-stabilized cubic zirconia, (ZrO2) with ternary oxide additions were grown using the laser float zone fiber processing technique. Ternary additions to the ZrO2-Y2O3 binary system were studied aimed at increasing strength while maintaining the high coefficient of thermal expansion of the binary system. Statistical methods aided in identifying the most promising ternary oxide candidate (Ta2O5, Sc2O3, and HfO2) and optimum composition. The yttria, range investigated was 14 to 24 mol % and the ternary oxide component ranged from 1 to 5 mol %. Hafnium oxide was the most promising ternary oxide component based on 816 C tensile strength results and ease of fabrication. The optimum composition for development was 81 ZrO2-14 Y203-5 HfO2 based upon the same elevated temperature strength tests. Preliminary results indicate process improvements could improve the fiber performance. We also investigated the effect of crystal orientation on strength.

Ritzert, F. J.↗

NASA NTRS2001

Contact Angles and Surface Tension of Germanium-Silicon Melts

Precise knowledge of material parameters is more and more important for improving crystal growth processes. Two important parameters are the contact (wetting) angle and the surface tension, determining meniscus shapes and surface-tension driven flows in a variety of methods (Czochralski, EFG, floating-zone, detached Bridgman growth). The sessile drop technique allows the measurement of both parameters simultaneously and has been used to measure the contact angles and the surface tension of Ge(1-x)Si(x) (0 less than or equal to x less than or equal to 1.3) alloys on various substrate materials. Fused quartz, Sapphire, glassy carbon, graphite, SiC, carbon-based aerogel, pyrolytic boron nitride (pBN), AIN, Si3N4, and polycrystalline CVD diamond were used as substrate materials. In addition, the effect of different cleaning procedures and surface treatments on the wetting behavior were investigated. Measurements were performed both under dynamic vacuum and gas atmospheres (argon or forming gas), with temperatures up to 1100 C. In some experiments, the sample was processed for longer times, up to a week, to investigate any changes of the contact angle and/or surface tension due to slow reactions with the substrate. For pure Ge, stable contact angles were found for carbon-based substrates and for pBN, for Ge(1-x)Si(x) only for pBN. The highest wetting angles were found for pBN substrates with angles around 170deg. For the surface tension of Ge, the most reliable values resulted in gamma(T) = (591- 0.077 (T-T(sub m)) 10(exp -3)N/m. The temperature dependence of the surface tension showed similar values for Ge(1-x)Si(x), around -0.08 x 10(exp -3)N/m K, and a compositional dependence of 2.2 x 10(exp -3)N/m at%Si.

Croell, A.↗