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NASA NTRS1998

Oscillatory/Chaotic Thermocapillary Flow Induced by Radiant Heating

There is a continuing need to understand the fluid physics occurring under low gravity conditions in processes such as crystal growth, materials processing, and the movement of bubbles or droplets. The fluid flow in such situations is often caused by a gradient in interfacial tension. If a temperature gradient is created due to a heat source, the resulting flow is called thermocapillary flow, a special case of Marangoni Convection. In this study, an experimental investigation was conducted using silicone oil in cylindrical containers with a laser heat source at the free surface. It was desired to determine the conditions under which steady, axisymmetrical thermocapillary flow becomes unstable and oscillatory three-dimensional flow states develop. The critical Marangoni number for each observed oscillatory state was measured as a function of the container aspect ratio and the dynamic Bond number, a measure of buoyant force versus ii thermocapillary force. Various oscillatory modes were observed during three- dimensional convection, and chaotic flow was reached in one test condition. The critical Marangoni numbers are compared with those measured in previous studies, and the power spectra and phase trajectories of the instantaneous surface temperature distributions are used to characterize the routes of transitions to the chaotic flow state. Results show that only superharmonic modes appear in the routes to chaos while infinite number of subharmonic modes occur in flow transitions for pure Rayleigh convection.

DeWitt, Kenneth J.↗

NASA NTRS2002

3-D Flow Field Diagnostics and Validation Studies using Stereoscopic Tracking Velocimetry

The measurement of 3-D three-component velocity fields is of great importance in both ground and space experiments for understanding materials processing and fluid physics. Here, we present the investigation results of stereoscopic tracking velocimetry (STV) for measuring 3-D velocity fields. The effort includes diagnostic technology development, experimental velocity measurement, and comparison with analytical and numerical computation. The advantages of STV stems from the system simplicity for building compact hardware and in software efficiency for continual near-real-time process monitoring. It also has illumination flexibility for observing volumetric flow fields from arbitrary directions. STV is based on stereoscopic CCD observations of particles seeded in a flow. Neural networks are used for data analysis. The developed diagnostic tool is tested with a simple directional solidification apparatus using Succinonitrile. The 3-D velocity field in the liquid phase is measured and compared with results from detailed numerical computations. Our theoretical, numerical, and experimental effort has shown STV to be a viable candidate for reliably quantifying the 3-D flow field in materials processing and fluids experiments.

Cha, Soyoung Stephen↗

NASA NTRS2012

Complex Protostellar Chemistry

Two decades ago, our understanding chemistry in protostars was simple -- matter either fell into the central star or was trapped in planetary-scale objects. Some minor chemical changes might occur as the dust and gas fell inward, but such effects were overwhelmed by the much larger-scale processes that occurred even in bodies as small as asteroids. The chemistry that did occur in the nebula was relatively easy to model because the fall from the cold molecular cloud into the growing star was a one-way trip down a well-known temperature pressure gradient; the only free variable was time. However, just over 10 years ago it was suggested that some material could be processed in the inner nebula, flow outward, and become incorporated into comets. This outward flow was confirmed when the Stardust mission returned crystalline mineral fragments from Comet Wild 2 that must have been processed close to the Sun before they were incorporated into the comet. In this week's Science Express, Ciesla and Sandford demonstrate that even the outermost regions of the solar nebula can be a chemically active environment. Their finding could have consequences for the rest of the nebula. Our understanding of the chemistry in protostellar systems has made enormous progress over the last few decades, fueled by an increased awareness of the complex dynamics of these evolving energetic nebulae. We can no longer consider just the simple local environment to explain the composition of a planet, asteroid, or comet as was done in the past, but must now consider chemical processes that might take place within the nebula as a whole as well as the probability of transport and mixing the products of such reactions throughout the system. just as we now find it impossible to explain the complex chemistry of the terrestrial atmosphere without reference to detailed transport models that interconnect highly dissimilar chemical environments, so chemical models of protostars and of the solar nebula must eventually treat these environments as tightly coupled, interactive systems. The demonstration that the chemistry on the surfaces of outward-flowing, dynamically mixing icy grain surfaces both mimics the chemistry in cold cloud cores and strikes at the central assumption of the photochemical self-shielding model for oxygen isotopes in solar system solids only adds emphasis to this conclusion.

Nuth, Joseph A., III↗

NASA NTRS2012

Complex Protostellar Chemistry

Two decades ago, our understanding of the chemistry in protostars was simple-matter either fell into the central star or was trapped in planetary-scale objects. Some minor chemical changes might occur as the dust and gas fell inward, but such effects were overwhelmed by the much larger scale processes that occurred even in bodies as small as asteroids. The chemistry that did occur in the nebula was relatively easy to model because the fall from the cold molecular cloud into the growing star was a one-way trip down a well-known temperature-pressure gradient; the only free variable was time. However, just over 10 years ago it was suggested that some material could be processed in the inner nebula, flow outward, and become incorporated into comets (1, 2). This outward flow was confirmed when the Stardust mission returned crystalline mineral fragments (3) from Comet Wild 2 that must have been processed close to the Sun before they were incorporated into the comet. In this week's Science Express, Ciesla and Sandford (4) demonstrate that even the outermost regions of the solar nebula can be a chemically active environment. Their finding could have consequences for the rest of the nebula.

Nuth, Joseph A., III↗

NASA NTRSDate not supplied

Packing and flow particle simulations

Granular material is present across natural and industrial processes on Earth and other planets. Granular particles show up in space exploration (lunar regolith), avalanches (boulders), food (coffee), construction (concrete powder) and manufacturing (additive manufacturing powder, battery slurries). Important phenomena emerge from large collections of granular particles. The size scales of the particles in granular material, 10 μm diameter or larger, makes particle-based simulations a tractable computational method. This seminar will present the packing and flow of granular matter using particle-based discrete element modeling simulations. Particles modeled with rotational friction only require as few as 2.6 contacts for mechanical stability, as opposed to 6 contacts for frictionless particles. Optimal parameters for in-space manufacturing particulate material are identified. Specifically, the maximum density and contacts occurs for a large-to-small particle volume ratio of 0.265. Stress and contact fabric fluctuations of flowing dry granular matter have power-law scaling with strain rate, and a kink. The pressure-dependent slope change kink could identify the transition between slower, quasistatic and faster, inertial flows.

granular↗

NASA NTRSDate not supplied

Packing and flow particle simulations

granular↗

NASA NTRS2014

On Characterizing Particle Shape

It is well known that particle shape affects flow characteristics of granular materials, as well as a variety of other solids processing issues such as compaction, rheology, filtration and other two-phase flow problems. The impact of shape crosses many diverse and commercially important applications, including pharmaceuticals, civil engineering, metallurgy, health, and food processing. Two applications studied here include the dry solids flow of lunar simulants (e.g. JSC-1, NU-LHT-2M, OB-1), and the flow properties of wet concrete, including final compressive strength. A multi-dimensional generalized, engineering method to quantitatively characterize particle shapes has been developed, applicable to both single particle orientation and multi-particle assemblies. The two-dimension, three dimension inversion problem is also treated, and the application of these methods to DEM model particles will be discussed. In the case of lunar simulants, flow properties of six lunar simulants have been measured, and the impact of particle shape on flowability - as characterized by the shape method developed here -- is discussed, especially in the context of three simulants of similar size range. In the context of concrete processing, concrete construction is a major contributor to greenhouse gas production, of which the major contributor is cement binding loading. Any optimization in concrete rheology and packing that can reduce cement loading and improve strength loading can also reduce currently required construction safety factors. The characterization approach here is also demonstrated for the impact of rock aggregate shape on concrete slump rheology and dry compressive strength.

Ennis, Bryan J.↗

NASA NTRS2012

Real-Time X-ray Radiography Diagnostics of Components in Solid Rocket Motors

Solid rocket motors (SRMs) typically use nozzle materials which are required to maintain their shape as well as insulate the underlying support structure during the motor operation. In addition, SRMs need internal insulation materials to protect the motor case from the harsh environment resulting from the combustion of solid propellant. In the nozzle, typical materials consist of high density graphite, carbon-carbon composites and carbon phenolic composites. Internal insulation of the motor cases is typically a composite material with carbon, asbestos, Kevlar, or silica fibers in an ablative matrix such as EPDM or NBR. For both nozzle and internal insulation materials, the charring process occurs when the hot combustion products heat the material intensely. The pyrolysis of the matrix material takes away a portion of the thermal energy near the wall surface and leaves behind a char layer. The fiber reinforcement retains the porous char layer which provides continued thermal protection from the hot combustion products. It is of great interest to characterize both the total erosion rates of the material and the char layer thickness. By better understanding of the erosion process for a particular ablative material in a specific flow environment, the required insulation material thickness can be properly selected. The recession rates of internal insulation and nozzle materials of SRMs are typically determined by testing in some sort of simulated environment; either arc-jet testing, flame torch testing, or subscale SRMs of different size. Material recession rates are deduced by comparison of pre- and post-test measurements and then averaging over the duration of the test. However, these averaging techniques cannot be used to determine the instantaneous recession rates of the material. Knowledge of the variation in recession rates in response to the instantaneous flow conditions during the motor operation is of great importance. For example, in many SRM configurations the recession of the solid propellant grain can drastically alter the flow-field and effect the recession of internal insulation and nozzle materials. Simultaneous measurement of the overall erosion rate, the development of the char layer, and the recession of the char-virgin interface during the motor operation can be rather difficult. While invasive techniques have been used with limited success, they have serious drawbacks. Break wires or make wire sensors can be installed into a sufficient number of locations in the charring material from which a time history of the charring surface can be deduced. These sensors fundamentally alter the local structure of the material in which they are imbedded. Also, the location of these sensors within the material is not known precisely without the use of an X-ray. To determine instantaneous recession rates, real-time X-ray radiography (X-ray RTR) has been utilized in several SRM experiments at PSU. The X-ray RTR system discussed in this paper consists of an X-ray source, X-ray image intensifier, and CCD camera connected to a capture computer. The system has been used to examine the ablation process of internal insulation as well as nozzle material erosion in a subscale SRM. The X-ray source is rated to 320 kV at 10 mA and has both a large (5.5 mm) and small (3.0 mm) focal spot. The lead-lined cesium iodide X-ray image intensifier produces an image which is captured by a CCD camera with a 1,000 x 1,000 pixel resolution. To produce accurate imagery of the object of interest, the alignment of the X-ray source to the X-ray image intensifier is crucial. The image sequences captured during the operation of an SRM are then processed to enhance the quality of the images. This procedure allows for computer software to extract data on the total erosion rate and the char layer thickness. Figure 1 Error! Reference source not found.shows a sequence of images captured during the operation the subscale SRM with the X-ray RTR system. The X-rayTR system, alignment procedure, uncertainty determination, and image analysis process will be discussed in detail in the full manuscript.

Cortopassi, A. C.↗

NASA NTRS2014

Ballistic Performance Model of Crater Formation in Monolithic, Porous Thermal Protection Systems

Porous monolithic ablative systems insulate atmospheric reentry vehicles from reentry plasmas generated by atmospheric braking from orbital and exo-orbital velocities. Due to the necessity that these materials create a temperature gradient up to several thousand Kelvin over their thickness, it is important that these materials are near their pristine state prior to reentry. These materials may also be on exposed surfaces to space environment threats like orbital debris and meteoroids leaving a probability that these exposed surfaces will be below their prescribed values. Owing to the typical small size of impact craters in these materials, the local flow fields over these craters and the ablative process afford some margin in thermal protection designs for these locally reduced performance values. In this work, tests to develop ballistic performance models for thermal protection materials typical of those being used on Orion are discussed. A density profile as a function of depth of a typical monolithic ablator and substructure system is shown in Figure 1a.

Miller, J. E.↗

NASA NTRS2000

Role of Vibration-Induced Streaming in Float-Zone Crystal Growth

This presentation will examine in detail the role of vibration-induced streaming flow in the context of float-zone crystal growth. It is very well known that during float-zone materials processing, the naturally occurring temperature gradients along the zone surface impose a thermocapillary flow in the zone. Under certain processing conditions, the thermocapillary flow can also become nonsteady (oscillatory). The presence of thermocapillary flow is detrimental to crystal quality, for it can promote non-uniform dopant distribution and crystal striations. To null this effect we have imposed a counter streaming flow in the zone, via end-wall vibration. This technique has been adapted to float-zone processing of Sodium Nitrate-Barium Nitrate eutectic alloys, under both steady and nonsteady thermocapillary flow conditions. The beneficial effects of counter streaming flow have been clearly brought out through the before and after comparisons of the crystal microstructure. In addition, we are also examining the theoretical underpinnings of the balancing of thermocapillary flows with vibration-driven counter flows in float-zones.

Anilkumar, A. V.↗

NASA NTRS2001

Role of Vibration-Induced Streaming in Float-Zone Crystal Growth

Anikumar, A. V.↗

NASA NTRS1996

The Microgravity Research Experiments (MICREX) Data Base

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.

Winter, C. A.↗

NASA NTRS1996

The Microgravity Research Experiments (MICREX) Data Base

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.

Winter, C. A.↗

NASA NTRS1990

LaRC-TPI 1500 composites fabricated using an aqueous slurry process

Unidirectional composites from unsized carbon fiber and LaRC-TPI matrix material were fabricated using 'high flow' and'medium flow' grades of the LaRC-TPI 1500 series of polyimides. Prepreg was drum-wound from a slurry composed of the polyimide powder dispersed in an aqueous solution of LaRC-TPI poly(amide acid). The poly(amide acid) was found to be an effective binding agent in the prepregging process. Composite short beam shear and flexure properties were measured at room and elevated temperatures (to 177 C) with both dry and moisture-saturated specimens. The mechanical properties observed for composites fabricated from the high and medium flow materials were virtually identical. Additionally, double cantilever beam measurements showed nearly equivalent fracture toughness for the two composite materials.

Towell, Timothy W.↗

NASA NTRS2004

Granular Material Flows with Interstitial Fluid Effects

The research focused on experimental measurements of the rheological properties of liquid-solid and granular flows. In these flows, the viscous effects of the interstitial fluid, the inertia of the fluid and particles, and the collisional interactions of the particles may all contribute to the flow mechanics. These multiphase flows include industrial problems such as coal slurry pipelines, hydraulic fracturing processes, fluidized beds, mining and milling operation, abrasive water jet machining, and polishing and surface erosion technologies. In addition, there are a wide range of geophysical flows such as debris flows, landslides and sediment transport. In extraterrestrial applications, the study of transport of particulate materials is fundamental to the mining and processing of lunar and Martian soils and the transport of atmospheric dust (National Research Council 2000). The recent images from Mars Global Surveyor spacecraft dramatically depict the complex sand and dust flows on Mars, including dune formation and dust avalanches on the slip-face of dune surfaces. These Aeolian features involve a complex interaction of the prevailing winds and deposition or erosion of the sediment layer; these features make a good test bed for the verification of global circulation models of the Martian atmosphere.

Hunt, Melany L.↗

NASA NTRS2004

Materials Processing in Space: Model Experiments aboard the International Space Station

Direct observation of fluid flow, bubble movement and solidification during controlled melting and solidification of succinonitrile were conducted in the glovebox facility of the International Space Station (ISS). The samples were processed in the Pore Formation and Mobility Investigation (PFMI) apparatus in the glovebox facility (GBX) on board 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. Real time visualization of the controlled directional melt back and resolidification reveals a number of microgravity dependent phenomena otherwise masked by Earth s gravity. These and some initial analysis of the observed events is presented.

Grugel, Richard↗

NASA NTRS2010

Advanced Flip Chips in Extreme Temperature Environments

The use of underfill materials is necessary with flip-chip interconnect technology to redistribute stresses due to mismatching coefficients of thermal expansion (CTEs) between dissimilar materials in the overall assembly. Underfills are formulated using organic polymers and possibly inorganic filler materials. There are a few ways to apply the underfills with flip-chip technology. Traditional capillary-flow underfill materials now possess high flow speed and reduced time to cure, but they still require additional processing steps beyond the typical surface-mount technology (SMT) assembly process. Studies were conducted using underfills in a temperature range of -190 to 85 C, which resulted in an increase of reliability by one to two orders of magnitude. Thermal shock of the flip-chip test articles was designed to induce failures at the interconnect sites (-40 to 100 C). The study on the reliability of flip chips using underfills in the extreme temperature region is of significant value for space applications. This technology is considered as an enabling technology for future space missions. Flip-chip interconnect technology is an advanced electrical interconnection approach where the silicon die or chip is electrically connected, face down, to the substrate by reflowing solder bumps on area-array metallized terminals on the die to matching footprints of solder-wettable pads on the chosen substrate. This advanced flip-chip interconnect technology will significantly improve the performance of high-speed systems, productivity enhancement over manual wire bonding, self-alignment during die joining, low lead inductances, and reduced need for attachment of precious metals. The use of commercially developed no-flow fluxing underfills provides a means of reducing the processing steps employed in the traditional capillary flow methods to enhance SMT compatibility. Reliability of flip chips may be significantly increased by matching/tailoring the CTEs of the substrate material and the silicon die or chip, and also the underfill materials. Advanced packaging interconnects technology such as flip-chip interconnect test boards have been subjected to various extreme temperature ranges that cover military specifications and extreme Mars and asteroid environments. The eventual goal of each process step and the entire process is to produce components with 100 percent interconnect and satisfy the reliability requirements. Underfill materials, in general, may possibly meet demanding end use requirements such as low warpage, low stress, fine pitch, high reliability, and high adhesion.

Ramesham, Rajeshuni↗

NASA NTRS1991

Human life support during interplanetary travel and domicile. II - Generic Modular Flow Schematic modeling

This paper describes the Generic Modular Flow Schematic (GMFS) architecture capable of encompassing all functional elements of a physical/chemical life support system (LSS). The GMFS can be implemented to synthesize, model, analyze, and quantitatively compare many configurations of LSSs, from a simple, completely open-loop to a very complex closed-loop. The GMFS model is coded in ASPEN, a state-of-the-art chemical process simulation program, to accurately compute the material, heat, and power flow quantities for every stream in each of the subsystem functional elements (SFEs) in the chosen configuration of a life support system. The GMFS approach integrates the various SFEs and subsystems in a hierarchical and modular fashion facilitating rapid substitutions and reconfiguration of a life support system. The comprehensive ASPEN material and energy balance output is transferred to a systems and technology assessment spreadsheet for rigorous system analysis and trade studies.

Farral, Joseph F.↗