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Development and Characterization of the Bonding and Integration Technologies Needed for Fabricating Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding technology, titanium interlayers (coatings and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness, and processing time were investigated. Electron microprobe analysis was used to identify the reaction formed phases. In the diffusion bonds, an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner interlayers of pure titanium and/or longer processing times resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Nondestructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig,Michael C.↗

Effect of salinity on the preservation of biomarkers in hypersaline microbial mat kerogens

Kerogen is the residue that remains after the minerals and organic compounds have been extracted from a rock using acid and organic solvents, respectively [1]. It is not only the largest organic carbon sink in the geological record but the best-preserved fraction due to its recalcitrance and ability to retain syngenetic source information during deposition [2]. Due to the complex, macromolecular, cross-linked polymeric structure of kerogen, it is difficult to analyse intact, often requiring breakdown into smaller subunits through thermal (pyrolysis) or chemical treatment (chemolysis) [3]. Saline and hypersaline environments host diverse microbial communities, which can trap and bind organic matrices such as cellular components (e.g., extracellular polymeric substances, cell wall, peptidoglycan, sheath material, etc.) with sediments, forming layered, laminated structures called microbial mats. Here we present depth profiles of two hypersaline cores through a microbial mat with differing total salinities. We looked at the composition of organic compounds released from kerogen during high temperature, hydrogen-assisted, pyrolysis to understand the effect of salinity on the composition and timing of their incorporation [4]. Field Site: The Exportadora del Sal S. A. (ESSA) saltern of Guerrero Negro (Baja California Sur, Mexico) lies within a typical sabhka environment adjacent to Laguna Ojo de Liebre. Note the spatial extent of the 13 major ponds of the ESSA system. The GN ponds thrive under well-monitored and stable conditions with steady state accretion and degradation of mat layers (around 0.5–1.4 cm per year). Organic mats typically attain up to 10 cm in thickness, depending on the location, which represents about 60 years of growth since these ponds were established. Sedimentation rate is rapid in these non-lithifying and non-mineralising mats, 1–1.5 cm per year. This environment is ideal for investigating in situ lipid preservation and diagenesis without the influence of constantly changing physical parameters. Methods: P4n5 and P5AB cores were collected as ~9 cm and 6.5 cm fresh cores, respectively, in June 2001 and September 2010, respectively from the ESSA saltern. The P4n5 core (9-9.1% salinity) was taken from Pond 4 near 5 and sub-divided into 10 layers. The P5AB core (11.2% salinity) was taken from Pond 5A near 5B and sub-divided into 8 layers. Lyophilised microbial mat powders were solvent-extracted using a modified Bligh-Dyer method and analysed by gas chromatography-mass spectrometry (GC-MS). Additionally, a subset of layers—layer 4 and layer 7—which represented active biomass and sediment-processed, respectively, were subjected to mild-acid methanolysis. The respective residues from conventional solvent extraction and acid methanolysis were loaded with a molybdenum sulfide catalyst and placed into a stainless-steel reactor. Samples were run on the hydropyrolysis set up (heated to 500 °C with 13-15 MPa of H2 pressure), extracted, and analysed by GC-MS. Results: Molecular profiles from the two ponds were significantly different and reflect the contributions of different photosynthetic and respiratory microbial communities to preserved organic matter. For example, the higher salinity P5AB core showed evidence of greater archaeal inputs (similarly observed in lab culture experiments [5]) as well as potential kerogen-bound carotenoids/carotenoid rearranged products or fragments. A hydrophobic emulsion formed during the acid methanolysis processing of layer 4 from both P4n5 and P5AB and layer 7 of P5AB. Hydropyrolysis of this hydrophobic residues released a greater abundance of polycyclic lipids relative to the pre-extracted control. Implications and Future Work: Catalytic hydropyrolysis of kerogen can rapidly generate abundant saturated pyrolysate products from the bound biomarker pool without altering the structures or stereochemistries of the products [6]. Chemical processing of solvent-extractable residues indicated that cellular matrices such as extracellular polymeric substances (EPS) may play a role in the sequestration of polycyclic lipid biomarkers such as steranes and hopanes. Their higher relative abundance compared to the pre-extracted control in the higher salinity layers and cores preliminarily aligns with this hypothesis, although further experiments are required to confirm this. It has been well-documented that EPS plays an important role in mineralisation, specifically carbonate formation, in microbial ecosystems. EPS can enhance calcium carbonate precipitation by providing diffusion-limited sites that create alkalinity gradients in response to microbial processes [7]. It has been experimentally demonstrated that salinity influences the total amount of EPS (both loosely- and tightly-bound) which increases with increasing salinity [8]. The higher salinity at Guerrero Negro switches the microbial population from filamentous Microcoleus to being dominated by Phormidium, Oscillatoria, and unicellular cyanobacteria. We demonstrated that lipid binding into kerogen via strong covalent linkages occurs at the very earliest stages of sedimentary diagenesis. We are currently investigating the influence of salinity on organic preservation through experimental and modelling approaches. Understanding how key biomarkers transform into preserved organic matter (i.e., from precursor biolipids to bound geolipids) in brine ecosystems will aid the search for organic biosignatures on other planetary bodies, especially Icy Moons and modern Mars.

hypersaline↗

Enhanced diffusion welding

Surfaces of unrecrystallized alloys are sanded and polished. This is followed by a two-step welding process by which the strength of the parent metal is retained at the weld joint. The first step forces the surfaces into intimate contact at a temperature where the metal still has good ductility. The second step causes diffusion, recrystallization, and grain growth across the original weld interface.

Holko, K. H.↗

Three-Dimensional Modeling of Guide-Field Magnetic Reconnection

The dissipation mechanism of guide field magnetic reconnection remains a subject of intense scientific interest. On one hand, one set of recent studies have shown that particle inertia-based processes, which include thermal and bulk inertial effects, provide the reconnection electric field in the diffusion region. On the other hand, a second set of studies emphasizes the role of wave-particle interactions in providing anomalous resistivity in the diffusion region. In this presentation, we analyze three-dimensional PIC simulations of guide-field magnetic reconnection. Specific emphasis will be on the question whether thermal-inertia processes, mediated by the electron pressure tensor, remain a viable dissipation mechanism in fully three-dimensional systems.

Hesse, Michael↗

Surface reaction and pore diffusion in flow-tube reactors

The interaction of gas diffusion with surface reaction in porous solids is discussed and applied specifically to heterogeneous rate measurements in flow-tube reactors. External diffusion to the outer surface of a reactive solid, internal diffusion within the pores, surface reaction, and laminar flow are considered. A procedure is developed to correct observed surface rate constants for the interaction of these processes. Measured surface areas and bulk densities are used to construct a semiempirical model for porous diffusion in vapor-formed HNO3-H2O ices which are used to simulate polar stratospheric cloud surfaces. The model is tested experimentally by varying the thickness of these ices from about 15 to 120 microns. The results are consistent with the model predictions and show that the HNO3-H2O ices used are highly porous, and the internal surface must be considered in calculating kinetic parameters from observed loss rates. The best fit of the data yields a tortuosity factor of 3.3 +/-1.1 for the ice substrates.

Keyser, Leon F.↗

Study of ceramic products and processing techniques in space

An analysis of the solidification kinetics of beta alumina in a zero-gravity environment was carried out, using computer-simulation techniques, in order to assess the feasibility of producing high-quality single crystals of this material in space. The two coupled transport processes included were movement of the solid-liquid interface and diffusion of sodium atoms in the melt. Results of the simulation indicate that appreciable crystal-growth rates can be attained in space. Considerations were also made of the advantages offered by high-quality single crystals of beta alumina for use as a solid electrolyte; these clearly indicate that space-grown materials are superior in many respects to analogous terrestrially-grown crystals. Likewise, economic considerations, based on the rapidly expanding technological applications for beta alumina and related fast ionic conductors, reveal that the many superior qualities of space-grown material justify the added expense and experimental detail associated with space processing.

Markworth, A. J.↗

Photochemistry of the atmosphere of Uranus

A detailed one-dimensional photochemical model incorporating vertical transport by eddy and molecular diffusion is used to study the importance of chemical and physical processes that control the hydrocarbon abundances in the stratosphere of Uranus. The study includes updated photochemical reaction rates and photolysis branching ratios; explicit calculation of the condensation rate of condensing species; and appropriate boundary conditions at the tropopause. It is found that the basic photochemical process generally produces low net conversion efficiencies of methane to higher hydrocarbons. However, even with these low efficiencies, the total condensation rate, which represents the net rate of conversion of methane to hydrocarbons, is roughly 2 x 10 to the -16th g/cm sec, in agreement with the upper range of the low condensation rate for the production of the stratospheric aerosol layer as determined by Pollack et al. (1987). Furthermore, a range of vertical transport rates is required to separately match the observational constraints on hydrocarbon abundances. The solar reflection data refer to the sunlit polar region of Uranus and require an eddy diffusion coefficient of K approx. = 50 sq cm/sec for globally averaged insolation or K approx = 1500 (Nh/N) exp 1/2 for overhead sun. The Voyager 2 Utraviolet Spectrometer solar occultation data refer to the equatorial regions, thus implying a large latitudinal gradient in stratospheric hydrocarbon abundance.

Summers, Michael E.↗

Silver plating ensures reliable diffusion bonding of dissimilar metals

Dissimilar metals are reliably joined by diffusion bonding when the surfaces are electroplated with silver. The process involves cleaning and etching, anodization, silver striking, and silver plating with a conventional plating bath. It minimizes the formation of detrimental intermetallic phases and provides greater tolerance of processing parameters.

Source record↗

Chondrules in Apollo 14 samples - Implications for the origin of chondritic meteorites.

Chondrules have been observed in several breccia samples returned by the Apollo 14 mission. These lunar chondrules are believed to have formed during a large impact event, perhaps the one that formed the Imbrian Basin. This suggests that some meteoritic chondrules are also formed by impact processes such as crystallization after shock melting and abrasion and diffusion in base-surge and fall-back deposits generated by impacts on planetary surfaces.

King, E. A., Jr.↗

The kinetics of ulvoespinel reduction - Synthetic study and applications to lunar rocks.

The kinetics of Fe2TiO4 reduction to FeTiO3 + Fe were studied using CO-CO2 gas mixtures with fO2 measured by a solid ceramic (calcia-zirconia) oxygen electrolyte cell. Isothermal rate studies at 900 C suggest that the mechanism of Fe2TiO4 reduction is one of nucleation and growth, where the growth stage may be controlled by the diffusion of the reactant through the product layer or volume diffusion. The activation energy for the growth stage of the process was determined to be 46 plus or minus 4 kcal/mole.

Mccallister, R. H.↗

Stress corrosion cracking of a titanium alloy in chloride-containing liquid environments

Ti-8 Al-1 Mo-1 V was tested in solvents containing chloride, bromide or iodide ions. It was found that the region II plateau velocity could be correlated with the inverse of the viscosity for several solvents. It seems most likely that this reflects the influence of the viscosity on the diffusion coefficient of some species involved in a mass transfer process which limits the crack growth. Associated tests were performed in which the potential, pH and concentration of Cl- were varied, in some of the same solutions as used for the viscosity tests. It is concluded from these tests that the absence of cathodic protection against cracking in solutions of low pH arises from an ohmic effect which isolates the crack tip from external potential control.

Smyrl, W. H.↗

Acceleration of energetic ions at the earth's bow shock

A simple analytical solution is presented which incorporates many of the processes believed to be important in the acceleration of the 'diffuse' component of energetic ions at the earth's bow shock, and which can account for many of the characteristics observed for these events. The solution can account for the observed spectral shape, the observed spatial dependence of the intensity, and the observed magnitude and spatial dependence of the anisotropy.

Lee, M. A.↗

Steady-state observations of geomagnetically trapped energetic heavy ions and their implications for theory

Data from the Heavy Ion Telescope on board Explorer 45 and the heavy ion channels on the ATS-6 spacecraft are used to describe the equatorial radial profiles of protons and He ions in the energy range of 0.1-1 MeV/nucleon. Measurements during a quiet period in June 1972 revealed that: fluxes of energetic protons and heavy ions inside L equals 4.5 are stable, with no observed decay; He ions of a given level are confined to the equatorial plane in a narrow L-range centered at Lmax; the equatorial differential flux ratio, compared on the basis of equal energy/ion, can exceed unity, indicating that He ion fluxes can be greater than equivalent energy proton fluxes; radial diffusion driven by variations of the magnetic field adequately models processes occurring in the inner magnetosphere for ion energies over 200 keV. The ATS-6 data from GEO found energetic heavy ions always present at L equals 6.6 and enhanced during magnetospheric substorms.

Fritz, T. A.↗

Adsorption and excess fission xenon

The adsorption of Xe and Kr on lunar soil 10084 was measured by a method that employs only very low fractions of monolayer coverage. Results are presented as parameters for calculation of the Henry constant for adsorption as a function of temperature. The adsorption potentials are about 3 kcal/mole for Kr and 5 kcal/mole for Xe; heating the sample in vacuum increased the Xe potential to nearly 7 kcal/mole. Henry constants at the characteristic lunar temperature are about 0.3 cu cm STP/g-atm. These data were applied to consider whether adsorption is important in producing the excess fission Xe effect characteristic of highland breccias. Sorption equilibrium with a transient lunar atmosphere vented fission Xe produces concentrations seven orders of magnitude lower than observed concentrations. Higher concentrations result because of the resistance of the regolith to upward diffusion of Xe. A diffusion coefficient of 0.26 sq cm/sec is estimated for this process.

Podosek, F. A.↗

Gas-phase hydrogen permeation through alpha-titanium - Surface film and dimensional effects

The process of hydrogen transport through alpha-Ti involves simultaneous diffusion and phase boundary reactions at both surfaces, with the relative effect on each surface depending on the extent of surface contamination as well as the physical dimensions of the titanium membrane used. It is shown by the present study that hydrogen permeation in commercially pure alpha-Ti increases exponentially with temperature and is dependent on the first power of the input pressure, whether the surface is as-polished, preoxidized or prenitrided. Permeation decreases in the case of the as-polished condition if nitride or oxide films are formed at the surface in contact with source hydrogen, while increasing slightly for the same condition if such films are formed at the hydrogen exit surface.

Shah, K. K.↗

Fabrication of multijunction high voltage concentrator solar cells by integrated circuit technology

Standard integrated circuit technology has been developed for the design and fabrication of planar multijunction (PMJ) solar cell chips. Each 1 cm x 1 cm solar chip consisted of six n(+)/p, back contacted, internally series interconnected unit cells. These high open circuit voltage solar cells were fabricated on 2 ohm-cm, p-type 75 microns thick, silicon substrates. A five photomask level process employing contact photolithography was used to pattern for boron diffusions, phorphorus diffusions, and contact metallization. Fabricated devices demonstrated an open circuit voltage of 3.6 volts and a short circuit current of 90 mA at 80 AMl suns. An equivalent circuit model of the planar multi-junction solar cell was developed.

Valco, G. J.↗

X-ray astronomy from Uhuru to HEAO-1

The nature of galactic and extragalactic X-ray sources is investigated using observations made with nine satellites and several rockets. The question of X-ray pulsars being neutron stars or white dwarfs is considered, as is the nature of Population II and low-luminosity X-ray stars, the diffuse X-ray emission from clusters of galaxies, the unidentified high-galactic-latitude (UHGL) sources, and the unresolved soft X-ray background. The types of sources examined include binary pulsars, Population II X-ray stars (both nonbursters and bursters) inside and outside globular clusters, coronal X-ray emitters, and active galactic nuclei. It is concluded that: (1) X-ray pulsars are strongly magnetized neutron stars formed in the evolution of massive close binaries; (2) all Population II X-ray stars are weakly magnetized or nonmagnetic neutron stars accreting from low-mass companions in close binary systems; (3) the diffuse emission from clusters is thermal bremsstrahlung of hot matter processed in stars and swept out by ram pressure exerted by the intergalactic gas; (4) most or all of the UHGL sources are active galactic nuclei; and (5) the soft X-ray background is emission from a hot component of the interstellar medium.

Clark, G. W.↗

Acceleration of low-energy protons and alpha particles at interplanetary shock waves

The low-energy protons and alpha particles in the energy range 30 keV/charge to 150 keV/charge associated with three different interplanetary shock waves in the immediate preshock and postshock region are studied using data obtained by the ISEE 3. The spatial distributions in the preshock and postshock medium are presented, and the dependence of the phase space density at different energies on the distance from the shock and on the form of the distribution function of both species immediately at the shock is examined. It is found that in the preshock region the particles are flowing in the solar wind frame of reference away from the shock and in the postshock medium the distribution is more or less isotropic in this frame of reference. The distribution function in the postshock region can be represented by a power law in energy which has the same spectral exponent for both protons and alpha particles. It is concluded that the first-order Fermi acceleration process can consistently explain the data, although the spectra of diffuse bow shock associated particles are different from the spectra of the interplanetary shock-associated particles in the immediate vicinity of the shock. In addition, the mean free path of the low energy ions in the preshock medium is found to be considerably smaller than the mean free path determined by the turbulence of the background interplanetary medium.

Scholer, M.↗