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The technology and economics of four methods of wafering silicon boules of large cross section are described. Slurry sawing using either blades or wires, and fixed abrasive sawing using the ID saw or by the FAST method, having the abrasive attached to wires which are arranged in a blade pack, are considered. The technical performance of each method is evaluated and cost/price estimates are summarized.
The cost of producing wafers from silicon ingots is a major component of the add-on price of silicon sheet. Economic analyses of the add-on price estimates and their sensitivity internal-diameter (ID) sawing, multiblade slurry (MBS) sawing and fixed-abrasive slicing technique (FAST) are presented. Interim price estimation guidelines (IPEG) are used for estimating a process add-on price. Sensitivity analysis of price is performed with respect to cost parameters such as equipment, space, direct labor, materials (blade life) and utilities, and the production parameters such as slicing rate, slices per centimeter and process yield, using a computer program specifically developed to do sensitivity analysis with IPEG. The results aid in identifying the important cost parameters and assist in deciding the direction of technology development efforts.
A method of desulfurizing coal is described in which chlorine gas is bubbled through an aqueous slurry of coal at low temperature below 130 degrees C., and at ambient pressure. Chlorinolysis converts both inorganic and organic sulfur components of coal into water soluble compounds which enter the aqueous suspending media. The media is separated after chlorinolysis and the coal dechlorinated at a temperature of from 300 C to 500 C to form a non-caking, low-sulfur coal product.
An improved method for markedly increasing the bond strength between a rigid, porous refractory material and non-rigid substrate by densifying the face of the rigid material opposing the substrate is discussed. Densification is accomplished by wetting the refractory material and then impregnating it with a composite slurry having a particle size to fill voids of the porous material.
Soil samples were fractionated and analyzed in order to assess the physical and chemical interactions of entrained soil with solid-rocket exhaust clouds. The sandy soil consisted primarily of quartz (silica) particles, 30 to 500 microns in diameter, and also contained seashell fragments. Differential and cumulative soil-mass size distributions are presented along with mineralogy, elemental compositions, and solution pH histories. About 90 percent of the soil mass consisted of particles 165 microns in diameter. Characteristic reaction times in aqueous HC1 slurries varied from a few minutes to several days, and capacities for reaction under acidic conditions varied from 10 to 40 g HCl/kg soil, depending on particle size. Airborne lifetimes of particles 165 microns are conservatively 30 min, and this major grouping is predicted to represent a small short-term chemical sink for up to 5% of the total HC1. The smaller and more minor fractions, below a 165 micron diameter, may act as giant cloud condensation nuclei over much longer airborne lifetimes. Finally, the demonstrated time dependency of neutralization is a complicating factor; it can influence the ability to deduce in-cloud HCl scavenging with reaction and can affect the accuracy of measured chemical compositions of near-field wet deposition.
The processing and oxidation resistance of fused Al-Si and Ni-Si slurry coatings on ATJ graphite was studied. Ni-Si coatings in the 70 to 90 percent Si range were successfully processed to melt, wet, and bond to the graphite. The molten coatings also infiltrated the porosity in graphite and reacted with it to form SiC in the coating. Cyclic oxidation at 1200 C showed that these coatings were not totally protective because of local attack of the substrate, due to the extreme thinness of the coatings in combination with coating cracks.
Laboratory scale experiments were conducted on two high volatile bituminous coals in a bench scale batch fluidized bed reactor. Chemical pretreatment and posttreatment of coals were tried as a means of enhancing desulfurization. Sequential chlorination and dechlorination cum hydrodesulfurization under modest conditions relative to the water slurry process were found to result in substantial sulfur reductions of about 80%. Sulfur forms as well as proximate and ultimate analyses of the processed coals are included. These studies indicate that a fluidized bed reactor process has considerable potential for being developed into a simple and economic process for coal desulfurization.
Cratering processes on icy satellites were simulated in a series of 102 laboratory impact experiments involving a wide range of target materials. For impacts into homogeneous clay slurries with impact energies ranging from five million to ten billion ergs, target yield strengths ranged from 100 to 38 Pa, and apparent viscosities ranged from 8 to 200 Pa s. Bowl-shaped craters, flat-floored craters, central peak craters with high or little relief, and craters with no relief were observed. Crater diameters increased steadily as energies were raised. A similar sequence was seen for experiment in which impact energy was held constant but target viscosity and strength progressively decreases. The experiments suggest that the physical properties of the target media relative to the gravitationally induced stresses determined the final crater morphology. Crater palimpsests could form by prompt collapse of large central peak craters formed in low target strength materials. Ages estimated from crater size-frequency distributions that include these large craters may give values that are too high.
Slicing is an important processing step for all technologies based on the use of ingots. A comparison of the economics of three slicing techniques shows that the fixed abrasive slicing technique (FAST) is superior to the internal diameter (ID) and the multiblade slurry (MBS) techniques. Factors affecting contact length are discussed, taking into account kerf width, rocking angle, ingot size, and surface speed. Aspects of blade development are also considered. A high concentration of diamonds on wire has been obtained in wire packs usd for FAST slicing. The material removal rate was found to be directly proportional to the pressure at the diamond tips.
Three ceramic, reusable surface insulation materials and two borosilicate glass coatings were used in the fabrication of tiles for the Space Shuttle orbiters. Approximately 77,000 tiles were made from these materials for the first three orbiters, Columbia, Challenger, and Discovery. Lessons learned in the development, scale up to production and manufacturing phases of these materials will benefit future production of ceramic reusable surface insulation materials. Processing of raw materials into tile blanks and coating slurries; programming and machining of tiles using numerical controlled milling machines; preparing and spraying tiles with the two coatings; and controlling material shrinkage during the high temperature (2100-2275 F) coating glazing cycles are among the topics discussed.
Techniques for studying the events directly preceding combustion in the liquid fuel sprays are being used to provide information as a function of space and time on droplet size, shape, number density, position, angle of flight and velocity. Spray chambers were designed and constructed for: (1) air-assist liquid fuel research sprays; (2) high pressure and temperature chamber for pulsed diesel fuel sprays; and (3) coal-water slurry sprays. Recent results utilizing photography, cinematography, and calibration of the Malvern particle sizer are reported. Systems for simultaneous measurement of velocity and particle size distributions using laser Doppler anemometry interferometry and the application of holography in liquid fuel sprays are being calibrated.
Bi-Polar nickel hydrogen design studies indicated a potential improvement in energy density and specific energy if positive electrodes could be manufactured in configurations of twice or more of the present normal thickness. Such electrodes would have to achieve similar active material loading, utilization, and cycle life to conventional 0.8mm I.P.U. nickel hydrogen electrodes. A capability for producing 1.0mm dry sinter and 1.5mm slurry sinter structures on production processes and equipment was demonstrated. The EPI/USAF electrochemical impregnation process proved capable of loading thick electrodes to 1.60 g/cubic centimeters void or higher. Sample electrodes incurred 2000 high rate stress cycles without significant structural or performance degradation. Formation regimes developed for thin plaque are not optimal for thick plaque and further investigation into electrode capacity build-up would seem warranted. Thick electrode technology development is continuing under other programs and shows promise of fulfilling the projected energy density and specific energy improvements.
The processing and oxidation resistance of fused Al-Si and Ni-Si slurry coatings on ATJ graphite was studied. Ni-Si coatings in the 70 to 90 percent Si range were successfully processed to melt, wet, and bond to the graphite. The molten coatings also infiltrated the porosity in graphite and reacted with it to form SiC in the coating. Cyclic oxidation at 1200 C showed that these coatings were not totally protective because of local attack of the substrate, due to the extreme thinness of the coatings in combination with coating cracks. Previously announced in STAR as N83-27019
Pressure-letdown valve combines quasi-porous-plug and vortex-chamber in one controllable unit. Valve useful in fossil-energy plants for reducing pressures in such erosive two-phase process streams as steam/water, coal slurries, or combustion gases with entrained particles. Quasi-Porous Plug consists of plenums separated by perforated plates. Number or size of perforations increases with each succeeding stage to compensate for expansion. In Vortex Chamber, control flow varies to control swirl and therefore difference between inlet and outlet pressures.
Machine drills, crushes, and feeds coal - and seeks out extra-hard inclusions. Auger mounted on gimbal, located at its center of gravity for ease of maneuvering. Opposing hydraulic cylinders cooperate to point auger under control of microprocessor. Its diamond teeth break up coal seam, it crushes coal fed to it by mining machine jaws, and its screw action pushes crushed coal into slurry-forming chamber.
Version of jaw miner operates without mechanical cutting and crushing. Forward-pointing jets of water dislodge and break up coal. Rearward-pointing jets further break up coal and force particles into slurry chamber. Oscillatingjet mechanism itself stays within "jaw" structure and protected from wear and tear associated with coal handling. All-jet machine generates even less dust than anger, therefore poses lesser explosion or health hazard.
A statistically designed experiment was conducted to determine optimum conditions for ball milling alpha-SiC in water. The influence of pH adjustment, volume percent solids loading, and mill rotational speed on grinding effectiveness was examined. An equation defining the effect of those milling variables on specific surface area was obtained. The volume percent solids loading of the slurry had the greatest influence on the grinding effectiveness in terms of increase in specific surface area. As grinding effectiveness improved, mill and media wear also increased. Contamination was minimized by use of sintered alpha-SiC milling hardware.
Photogeologic studies of the Elysium volcanic province appear to provide a specific example of the importance of volcanic-ice interaction to produce the channels of Hrad and Granicus Valles. In addition, these studies shows that the channels lie on the surface of a large sedimentary deposit which is interpreted as an accumulation of volcanic debris flows or lahars. In spite of some similarities with Martian outflow channels, this latter difference may distinguish the Elysium channels from other types of Martian channels. Geologic relations are described which demonstrate that the debris flows formed amidst other volcanic activity in the Elysium region thereby suggesting that the magmatism was important to the generation of the mobilizing liquid. The lahars resulted from the melting of ground ice and liquefaction of subsurface materials. The intersection of this fluid reservoir with the regional fracture system lead to the rapid expulsion of a muddy slurry down the steep western slope of the province.