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Uncontaminated environments for highly-pure material processing provided within completely sealed levitation chamber that suspends particles by acoustic excitation. Technique ideally suited for material processing in low gravity environment of space.
The possible applications of technology of materials processing in low gravity is discussed. A special office established by NASA to familiarize commercial organizations with materials processing in low gravity is described. This office provides information on present research and will, if requested, hold a seminar to present the technological and business aspects of joint investigations and joint endeavors to interested organizations. Arrangements can be made for visits to laboratories where ground based research is in progress.
The main research activities have been directed toward the study of the Robot Operated Materials Processing System (ROMPS), developed at GSFC under a flight project to investigate commercially promising in-space material processes and to design reflyable robot automated systems to be used in the above processes for low-cost operations. The research activities can be divided into two phases. Phase 1 dealt with testing of ROMPS robot mechanical interfaces and compliant device using a Stewart Platform testbed and Phase 2 with computer simulation study of the ROMPS robot control system. This report provides a summary of the results obtained in Phase 1 and Phase 2.
An electronic data base identifying over 800 fluids and materials processing experiments performed in a low-gravity environment has been created at NASA Marshall Space Flight Center. The compilation, called MICREX (MICrogravity Research Experiments), was designed to document all such experimental efforts performed (1) on U.S. manned space vehicles, (2) on payloads deployed from U.S. manned space vehicles, and (3) on all domestic and international sounding rockets (excluding those of China and the former U.S.S.R.). Data available on most experiments include (1) principal and co-investigators (2) low-gravity mission, (3) processing facility, (4) experimental objectives and results, (5) identifying key words, (6) sample materials, (7) applications of the processed materials/research area, (8) experiment descriptive publications, and (9) contacts for more information concerning the experiment. This technical memorandum (1) summarizes the historical interest in reduced-gravity fluid dynamics, (2) describes the experimental facilities employed to examine reduced gravity fluid flow, (3) discusses the importance of a low-gravity fluids and materials processing data base, (4) describes the MICREX data base format and computational World Wide Web access procedures, and (5) documents (in hard-copy form) the descriptions of the first 600 fluids and materials processing experiments entered into MICREX.
An electronic data base identifying over 800 fluids and materials processing experiments performed in a low-gravity environment has been created at NASA Marshall Space Flight Center. The compilation, called MICREX (MICrogravity Research Experiments), was designed to document all such experimental efforts performed (1) on U.S. manned space vehicles, (2) on payloads deployed from U.S. manned space vehicles, and (3) on all domestic and international sounding rockets (excluding those of China and the former U.S.S.R.). Data available on most experiments include (1) principal and co-investigators, (2) low-gravity mission, (3) processing facility, (4) experimental objectives and results, (5) identifying key words, (6) sample materials, (7) applications of the processed materials/research area, (8) experiment descriptive publications, and (9) contacts for more information concerning the experiment. This technical memorandum (1) summarizes the historical interest in reduced-gravity fluid dynamics, (2) describes the experimental facilities employed to examine reduced gravity fluid flow, (3) discusses the importance of a low-gravity fluids and materials processing data base, (4) describes the MICREX data base format and computational World Wide Web access procedures, and (5) documents (in hard-copy form) the descriptions of the first 600 fluids and materials processing experiments entered into MICREX.
The Robot operated Material Processing in Space (RoMPS) experiment is being performed to explore the marriage of two emerging space commercialization technologies: materials processing in microgravity and robotics. This concept review presents engineering drawings and limited technical descriptions of the RoMPS programs' electrical and software systems.
The fabrication of several composite structural articles including DC-10 upper aft rudders, L-1011 vertical fins and composite biomedical appliances are discussed. Innovative composite processing methods are included.
The materials processing experiments in space, conducted on the SPAR 4 Black Brant VC rocket, are described and discussed. The SPAR 4 payload configuration, the rocket performance, and the flight sequence are reported. The results, analyses, and anomalies of the four experiments are discussed. The experiments conducted were the uniform dispersions of crystallization processing, the contained polycrstalline solidification in low gravity, the containerless processing of ferromagnetic materials, and the containerless processing technology. The instrumentation operations, payload power relay anomaly, relay postflight operational test, and relay postflight shock test are reported.
The Space Shuttle Challenger, with Spacelab 3 as its payload, was launched into orbit April 29, 1985. The mission, number 51-B, emphasized materials processing in space, although a wide variety of experiments in other disciplines were also carried onboard. One of the materials processing experiments on this flight is described, specifically the growth of single crystals of mercuric iodide by physical vapor transport.
Spray forming is a materials processing technology in which a bulk liquid metal is converted to a spray of fine droplets and deposited onto a substrate or pattern to form a near-net-shape solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g. refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. The Idaho National Engineering Laboratory is developing a unique spray-forming method, the Controlled Aspiration Process (CAP), to produce near-net-shape solids and coatings of metals, polymers, and composite materials. Results from two spray-accompanying technical and economic benefits. These programs involved spray forming aluminum strip reinforced with SiC particulate, and the production of tooling, such as injection molds and dies, using low-melting-point metals.
Space medicine research in the 21st century will continue to focus on the four major areas including: (1) expansion of the current incomplete knowledge base of clinical and subclinical physiological changes due to microgravity; (2) development of countermeasures to extend the capabilities of the human performance envelope in extended duration flights; (3) development of novel methods for delivering all aspects of a comprehensive health care system in extreme remote conditions: and (4) further research and application of systems for biological materials processing. New space transportation vehicles will place unique physiologic and human factors demands on the human system, while providing better access to platforms for materials processing. Success in meeting the demands in each of the noted research areas will require an extensive, interactive team approach. Personnel from the medical research,operational, developmental, and basic science communities will be essential to success.
The use of plasmas to process materials has become widespread throughout the semiconductor industry. Plasmas are used to modify the morphology and chemistry of surfaces. We report on initial plasma processing experiments using the Fisk Plasma Source. Metallic and semiconductor thin films deposited on a silicon substrate have been exposed to argon plasmas. Results of microscopy and chemical analyses of processed materials are presented.
In order to provide new furnace technology to accommodate microgravity research studies and commercial applications in material processes, research has been initiated on the development of the Programmable-Multi-zone Furnace (PMZF). The PMZF is described as a multi-user materials processing furnace facility that is composed of thirty or more heater elements in series on a muffle tube or in a stacked ring-type configuration and independently controlled by a computer. One of the aims of the PMZF project is to allow furnace thermal gradient profiles to be reconfigured without physical modification of the hardware by creating the capability of reconfiguring thermal profiles in response to investigators' requests. The future location of the PMZF facility is discussed; the preliminary science survey results and preliminary conceptual designs for the PMZF are presented; and a review of multi-zone furnace technology is given.
A major cause of project failure can be attributed to an emphasized focus on end products and inadequate attention to resolving development risks during the initial phases of a project. The initial phases of a project, which we will call the "study period", are critical to determining project scope and costs, and can make or break most projects. If the requirements are not defined adequately, how can the scope be adequately determined, also how can the costs of the entire project be effectively estimated, and how can the risk of project success be accurately assessed? Using the proper material specifications and standards and incorporating these specifications and standards in the design process should be considered inherently crucial to the technical success of a project as just as importantly, crucial to the cost and schedule success. This paper will intertwine several important aspects or considerations for project success: 1) Characteristics of a "Good Material Requirement"; 2) Linking material requirements to the implementation of "Design for Manufacturing"; techniques and 3) The importance of decomposing materials requirements during the study phase/development phase to mitigate project risk for the maturation of technologies before the building of hardware.
The design of the Skylab missions, 1973 to 1974, was intended to exclude any direct handling of hazardous, toxic, or reactive materials. The materials processing facility and multipurpose furnace provided a contained environment for conducting metals melting, brazing, sphere forming, and crystal growth experiments. At the end of the third mission, following the completion of all other experiments, the materials processing facility was used for a series of flammability experiments. The flammability tests were done last because of the contamination expected from the burning of the materials within the facility. The flammability tests demonstrated a number of peculiar effects that have implications for future design (fire detection, location, and suppression/control). Although the results of the flammability tests contain lessons appropriate to planning, a number of events during the flight illustrate situations or conditions that pose considerations beyond the commonly accepted range of concern for safety-related matters. This presentation includes a discussion of: Skylab flammability studies and the implications for fire suppression/control; false fire alarms and the Skylab fire detection system; space environmental effects on materials that are normally benign; spills/release of contaminants; the detrimental effect that the release of non-hazardous materials have on detection systems; and the problem of locating sources/originating point of hazards.
The HEAO-3 Heavy Nuclei Experiment has measured abundances of elements from Ar-18 to U-92 in the cosmic rays. The results on the ultraheavy elements, those with atomic numbers greater than 30, indicate that the source of the cosmic rays contain a mixture of r-process and s-process material similar to that found in the solar system. This result is at variance with previous indications that the sources are greatly enhanced with freshly synthesized r-process material. Apparent discrepancies between the results and the accepted solar-system abundance have led to a reexamination of data on photospheric abundances of Ge and Pb, resulting in suggested reductions in their values.
The use of solar system resources for human industry can be viewed as a natural extension of the continual growth of our species' habitat. Motivations for human activities in space can be discussed in terms of five distinct areas: (1) information processing and collection; (2) materials processing; (3) energy production to meet terrestrial power needs; (4) the use of extraterrestrial materials; and (5) disaster avoidance. When considering 21st-Century activities in space, each of these basic motivations must be treated in light of issues likely to be relevant to the 21st-Century earth. Many of the problems facing 21st-Century earth may stem from the need to maintain the world population of 8 to 10 billion people as is projected from expected growth rates. These problems are likely to include managing the impact of industrial processes on the terrestrial biosphere while providing adequate energy production and material goods for the growing population. The most important human activities in space in the latter half of the 21st Century may be associated with harnessing the resources of the near-earth asteroids for industrial processes. These above topics are discussed with an emphasis on space industrialization.
Anodizing technique allows independent selection of coating thermal emittance and solar absorption. Process has three phases: initial material processing, which prepares material and establishes initial values of emittance and absorption; anodizing with chromic acid solution, which determines final values; and material postprocessing. Stability tests show less than 15 percent coating degradation over 2,000 hour solar exposure.