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Tube crucible and furnace are used to separate eutectic mixture from trial-melt ingot. As ingot is a slowly heated to melting point, initial surface meeting will be eutectic mixture. Molten metal is collected at bottom of crucible, where it is solidified.
The existence of iron meteor oblation spheres in deep sea sediments was known for over a century. These spheres generally were believed to be composed of either pure magnetite and wustite or an oxide shell surrounding a NiFe metal core. A large number of 300 micron to 600 micron spheres found were pure oxide spheres, usually containing a solitary 10 micron platinum group nugget (pgn) composed almost entirely of group VIII metals. Twelve PGN's were analyzed and most had chondritic abundances with some depletions that correlate with element volatility. PGN formation by oxidation of a molten metal sphere entering the atmosphere cannot occur if the oxygen abundance in the atmosphere is less than half of its present value. The first appearance of PGN's in the geological record should mark when, in the Earth's history, oxygen rose to this level.
Pallasites are mixtures of metal with magnesian olivine. Most have similar metal compositions and olivine oxygen isotopic compositions; these are the main-group pallasites (PMG). The Eagle Station grouplet of pallasites (PES) have distinctive metal and olivine compositions and oxygen isotopic compositions. Pallasites are thought to have formed at the core-mantle boundary of their parent asteroids by mixing molten metal with solid olivine of either cumulatic or restitic origin. We have continued our investigation of pallasite olivines by doing in situ trace element analyses in order to further constrain their origin. We determined Al, P, Ca, Ga and first row transition element contents of olivine grains from suite of PMG and PES by LA-ICP-MS at JSC. Included in the PMG suite are some that have anomalous metal compositions (PMG-am) and atypically ferroan olivines (PMG-as). Our EMPA work has shown that there are unanticipated variations in olivine Fe/Mn, even within those PMG that have uni-form Fe/Mg. Manganese is homologous with Fe2+, and thus can be used the same way to investigate magmatic fractionation processes. It has an advantage for pallasite studies in that it is unaffected by redox exchange with the metal. PMG can be divided into three clusters on the basis of Mn/Mg; low, medium and high that can be thought of as less, typically and more fractionated in an igneous sense. The majority of PMG have medium Mn/Mg ratios. PMG-am occur in all three clusters; there does not seem to be any relationship between putative olivine igneous fractionation and metal composition. The PMG-as and one PMG-am make up the high Mn/Mg cluster; no PMG are in this cluster. The high Mn/Mg cluster ought to be the most fractionated (equivalent to the most Fe-rich in igneous suites), yet they have among the lowest contents of incompatible lithophile elements Al and Ti and the two PMG-as in this cluster also have low Ca and Sc contents. This is inconsistent with simple igneous fractionation on a single, initially homogeneous parent asteroid. For Al and Ti, the low and high Mn/Mg clusters have generally uniform contents, while the medium cluster has wide ranges. This is also true of analyses of duplicate grains from the medium cluster pallasites which can have very different Al and Ti contents. Those from the low and high clusters do not. These observations suggest that pallasite olivines are not cumulates, but rather are restites from high degrees of melting. The moderately siderophile elements P and Ga show wide ranges in the high Mn/Mg cluster, but very uniform compositions in the medium cluster, opposite the case for Al and Ti. There is no correlation of P or Ga and Fe/Mn as might be expected if redox processes controlled the contents of moderately siderophile elements in the olivines. The lack of correlation of P could reflect equilibration with phosphates, although there is no correlation of Ca with P as might be expected
The scientific objective of the Isothermal Dendritic Growth Experiment (IDGE) is to test fundamental assumptions about dendritic solidification of molten materials. "Dendrites"-- from the ancient Greek word for tree--are tiny branching structures that form inside molten metal alloys when they solidify during manufacturing. The size, shape, and orientation of the dendrites have a major effect on the strength, ductility (ability to be molded or shaped), and usefulness of an alloy. Nearly all of the cast metal alloys used in everyday products (such as automobiles and airplanes) are composed of thousands to millions of tiny dendrites. Gravity, present on Earth, causes convection currents in molten alloys that disturb dendritic solidification and make its precise study impossible. In space, gravity is negated by the orbiting of the space shuttle. Consequently, IDGE (which was conducted on the space shuttle) gathered the first precise data regarding undisturbed dendritic solidification. IDGE is a microgravity materials science experiment that uses an apparatus which was designed, built, tested, and operated by people from the NASA Lewis Research Center. This experiment was conceived by the principal investigator, Professor Martin E. Glicksman, from Rensselaer Polytechnic Institute in Troy, New York. The experiment was a team effort of Lewis civil servants, contractors from Aerospace Design & Fabrication Inc. (ADF), and personnel at Rensselaer.
Research in metallurgical processing to study the effects of reduced gravity started with Apollo 14 and advanced with Skylab. Experiments provided specimens for analysis which solidified while constrained and while freely floating, which contained a mixture of normally immiscible materials, demonstrated enhanced capillary flow, solubility and ordered growth of a directionally solidified eutectic. The smaller, equiaxed grain structure obtained in reduced gravity compared to the larger, elongated grains obtained in one gravity indicate a difference in convection due to gravity in constrained solidification. Freely floating nickel alloy specimens showing metallic gas evolution at low pressure and reduced gravity suggest reduced pressure reactions which cannot occur on earth even in high vacuum chambers due to the hydrostatic head in the molten metal. Directionally solidified eutectics showed fewer termination defects when grown in reduced gravity. These are a few of the differences observed due to reduced gravity which could have important consequences on the future of metallurgy. In this paper we attempt to correlate the results of several Skylab solidification experiments.
The Soft Plasma Arc (SPA) process was devised to avoid interactions between backshield and full penetration mode plasma jet in welding 2195 aluminum-lithium alloy. Occasional sudden and mysterious losses in penetration were encountered in flat position SPA welding. To understand what was happening a model of the dynamics of the molten metal meniscus at the root of the weld was worked out. When the power input to the weld P(sub in) exceeds the power leakage P(sub out) the difference in power is absorbed by an increase in the molten weld pool volume V, Rho X L(SUB m) X (d(V)/dt)) = P(sub in) - P(sub out) where rho is the density and L(sub m) the specific heat of the weld metal.
The combustion of metals is a field with important practical applications in rocket propellants, high-temperature flames, and material synthesis. Also, the safe operation of metal containers in high-pressure oxygen systems and with cryogenic fuels and oxidizers remains an important concern in industry. The increasing use of metallic components in spacecraft and space structures has also raised concerns about their flammability properties and fire suppression mechanisms. In addition, recent efforts to embark on unmanned and manned planetary exploration, such as on Mars, have also renewed the interest in metal/carbon-dioxide combustion as an effective in situ resource utilization technology. In spite of these practical applications, the understanding of the combustion properties of metals remains far behind that of the most commonly used fuels such as hydrocarbons. The lack of understanding is due to the many problems unique to metal- oxidizer reactions such as: low-temperature surface oxidation prior to ignition, heterogeneous reactions, very high combustion temperatures, product condensation, high emissivity of products, and multi-phase interactions. Very few analytical models (all neglecting the influence of gravity) have been developed to predict the burning characteristics and the flame structure details. Several experimental studies attempting to validate these models have used small metal particles to recreate gravity-free conditions. The high emissivity of the flames, rapid reaction, and intermittent explosions experienced by these particles have made the gathering of any useful information on burning rates and flame structure very difficult. The use of a reduced gravity environment is needed to clarify some of the complex interactions among the phenomena described above. First, the elimination of the intrusive buoyant flows that plague all combustion phenomena is of paramount importance in metal reactions due to the much higher temperatures reached during combustion. Second, a low-gravity environment is absolutely essential to remove the destructive effect of gravity on the shape of a molten metal droplet in order to study a spherically symmetric condition with large bulk samples. The larger size of the spherical metal droplet and the longer burning times available in reduced gravity extend the spatial and temporal dimensions to permit careful probing of the flame structure and dynamics. Third, the influence of the radiative heat transfer from the solid oxides can be studied more carefully by generating a stagnant spherical shell of condensed products undisturbed by buoyancy.
Steel and tantalum apparatus contains various ternary alloys of cadmium, zinc, and magnesium used in pyrochemical processes for the recovery of uranium-base reactor fuels. These materials exhibit good corrosion resistance at the high temperatures necessary for fuel separation in liquid metal-molten salt solvents.
Various theories regarding lunar and Mercurian magnetic properties are discussed in terms of the thermal evolutions of these bodies. In particular, the extinct dynamo, the primordial field of external origin, local mechanisms, and the active dynamo hypotheses are reviewed. The theory involving magnetization by an internal dynamo is applied to Mercury, noting that it implies the existence of a molten metallic core, or shell. Possible sources of the energy required for core differentiation are discussed, including accretional heating, long-lived radioactive isotopes, and other radioactive heat sources. Thermal processes which might keep the core molten are suggested along with processes permitting the flow of heat through the mantle. Conclusions suggested by the dynamo hypothesis are reviewed in terms of current models of the thermal evolution of Mercury and the moon.
The Vacuum Plasma Spray (VPS) Laboratory at NASA's Marshall Space Flight Center, working with the Jet Propulsion Laboratory, has developed and demonstrated a fabrication technique using the VPS process to form anode and cathode sections for a Lorentz force accelerator made from tungsten. Lorentz force accelerators are an attractive form of electric propulsion that provides continuous, high-efficiency propulsion at useful power levels for such applications as orbit transfers or deep space missions. The VPS process is used to deposit refractory metals such as tungsten onto a graphite mandrel of the desired shape. Because tungsten is reactive at high temperatures, it is thermally sprayed in an inert environment where the plasma gun melts and deposits the molten metal powder onto a mandrel. A three-axis robot inside the chamber controls the motion of the plasma spray torch. A graphite mandrel acts as a male mold, forming the required contour and dimensions for the inside surface of the anode or cathode of the accelerator. This paper describes the processing techniques, design considerations, and process development associated with the VPS forming of Lorentz force accelerator components.
Spherical shells of submillimeter size are sought as ICF targets. Such shells must be dimensionally precise, smooth, of high strength, and composed of a high atomic number material. A technology for the production of shells based upon the hydrodynamic instability of an annular jet of molten metal is described. Shells in the 0.7-2.0 mm size range have been produced using tin as a test material. Specimens exhibit good sphericity, fair concentricity, and excellent finish over most of the surface. Work involving a gold-lead-antimony alloy is in progress. Droplets of this are amorphous and possess superior surface finish. The flow of tin models that of the alloy well; experiments on both metals show that the technique holds considerable promise.
A liquid catholyte for a battery based on liquid metal such as sodium anode and a solid, ceramic separator such as beta alumina (BASE) comprises a mixture of a Group I-III metal salt such as sodium tetrachloroaluminate and a minor amount of an organic carbonitrile depolarizer having at least one adjacent ethylenic band such as 1 to 40 percent by weight of tetracyanoethylene. The tetracyanoethylene forms an adduct with the molten metal salt.
Ground based studies of two proposed experiments which were to be conducted aboard the Skylab Laboratory are reported; metals melting experiment, and sphere forming experiment. These studies were conducted with the objectives of clarifying the effects of gravity and optimizing the experiments within the constraints of existing hardware. All process phenomena were considered, with particular attention given to adhesion-cohesion studies with emphasis on the fluid dynamics of the molten metal. Detailed thermal histories were generated for three-dimensional specimen geometry including radiation, conduction and vaporization losses with allowances for variable properties. In addition quantitative techniques were used to establish the gravitational level (magnitude and direction) for KC-135 aircraft flights and the actual Skylab mission for both experiments.
Three metal-rich meteorites - Mt. Egerton, Horse Creek, and LEW 88055 - were studied and it is suggested that they formed in the aubrite parent body. LEW 85369 and 88631 may also have a common origin, but these rocks have not yet been studied in detail. This body was probably heated to about 1600 C by a very strong heat source. While molten, metal agglomerated into sizeable nodules which never segregated efficiently to form a core, but were trapped in the silicate mantle. Different clasts and lithologies in aubrites solidified and cooled under local equilibrium conditions of oxygen fugacity, and with different thermal histories. Impacts mixed clasts from throughout the parent body, creating the typical aubrite breccias.
An improved method of filling a molding flask with sand and compacting the sand around a refractory-coated foam mold pattern has been developed for incorporation into the lost-foam metal-casting process. In comparison with the conventional method of sand filling and compaction, this method affords more nearly complete filling of the space around the refractory-coated foam mold pattern and more thorough compaction of the sand. In so doing, this method enables the sand to better support the refractory coat under metallostatic pressure during filling of the mold with molten metal.
Ultrahigh temperature ceramics (UHTCs) are a class of materials that include the diborides of metals such as hafnium and zirconium. The materials are of interest to NASA for their potential utility as sharp leading edges for hypersonic vehicles. Such an application requires that the materials be capable of operating at temperatures, often in excess of 2,000 C. UHTCs are highly refractory and have high thermal conductivity, an advantage for this application. UHTCs are potentially applicable for other high-temperature processing applications, such as crucibles for molten-metal processing and high-temperature electrodes. UHTCs were first studied in the 1960 s by the U.S. Air Force. NASA s Ames Research Center concentrated on developing materials in the HfB2/SiC family for a leading-edge application. The work focused on developing a process to make uniform monolithic (2-phase) materials, and on the testing and design of these materials. Figure 1 shows arc-jet models made from UHTC materials fabricated at Ames. Figure 2 shows a cone being tested in the arc-jet. Other variations of these materials being investigated elsewhere include zirconium based materials and fiber-reinforced composites. Current UHTC work at Ames covers four broad topics: monoliths, coatings, composites, and processing. The goals include improving the fracture toughness, thermal conductivity and oxidation resistance of monolithic UHTCs and developing oxidation-resistant UHTC coatings for thermal-protection-system substrates through novel coating methods. As part of this effort, researchers are exploring compositions and processing changes that have yielded improvements in properties. Computational materials science and nanotechnology are being explored as approaches to reduce materials development time and improve and tailor properties.
The question of whether or not Mercury could contain a molten metallic core is investigated by studying the possible thermal evolution of a metallic core in that planet. The calculations involve the solution of the equation of heat conduction for a spherically symmetric body with internal heat sources, modifications to take account of the latent heat of fusion as well as the redistribution of radioactive heat sources as a consequence of melting, the terrestrial Fe/U ratio, and a Th/U ratio of 3.7. The temperature profile predicted by the calculations for a period of 4.6 billion years indicates that the inner 1400 km of the core would now be solid while the outer 500 km would be molten. It is emphasized that this result is a direct consequence of a discontinuity in melting temperatures at the core-mantle boundary and that although a dynamo is possible, it would have to be driven mechanically rather than by thermal convection.
In several crystal growth processed based on capillarity, a melt comes into contact with a crucible wall at an angle defined as the contact angle. For molten metals and semiconductors, this contact angle is dependent upon both the crucible and melt material and typical values fall in the range 80-170deg. However, on a microscopic scale, there does not exist a precise and sharp contact angle but rather the melt and solid surfaces merge smoothly and continuously over a distance of up to several micrometers. Accurate modeling requires a more advanced treatment of this interaction. The interaction between the melt and solid surfaces can be calculated by considering two forces: a short-range repulsive force and a longer range (up to a few micrometers) Casimir force. The Casimir force between the two bodies of complex geometry is calculated using a retarded temperature Green's function (Matsubara type) for the photon in the medium. The governing equations are cast in the form of a set of boundary integral equations which are then solved numerically for the case of molten Ge on SiO2. The shape of the molten surface approaching the flat solid body is determined, and the contact angle is defined as the angle between the two surfaces at the microscopically asymptotic distance of 1-2 micrometers. The formulation of this model and the results of the numerical calculations will be presented and discussed.