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Compositions of glasses and alloys analyzed and corrected in real time. Spectral analysis and temperature measurement performed simultaneously on molten material in container, such as open-hearth furnace, crucible or tank of continuous furnace. Speed of analysis makes it possible to quickly measure concentration of volatile elements depleted by prolonged heating.
Many of the experiments to be carried out in the Space Shuttle will require containerless processing techniques that will provide manipulation and control of weightless (molten) materials without physical contact with container walls or other holding devices. The variety of containerless processing technologies now being developed for space- and ground-based materials processing facilities is surveyed. It is shown how the utilization of air jets or high-intensity acoustic, electromagnetic, or electrostatic fields can produce forces that support and manipulate materials. Most of the present containerless research seeks to develop high-temperature systems capable of melting and resolidifying materials. An introduction to available NASA test facilities is provided.
Polycrystalline silicon for solar cells produced at low cost. Molten silicon poured from quartz trough onto moving carbon-coated ceramic substrate. Doctor blade spreads liquid silicon evenly over substrate. Molten material solidifies to form sheet of polycrystalline silicon having photovoltaic conversion efficiency greater than 10 percent. Method produces 100-um-thick silicon coatings at speed 0.15 centimeter per second.
A brief review of containerless processing activities sponsored by NASA's Microgravity Science Division is presented. Attention is given to ground based systems such as shot tower processing of molten materials, single axis levitation and flight processing concepts including BeO processing aboard the Space Shuttle, a medium temperature three-axis acoustic positioning system and a high temperature single axis acoustic positioning system. In the future, more sophisticated experiments will be conducted using improved measurement techniques which will quantitatively define the advantages of containerless processing, as well as improve the understanding of nuclear kinetics and of the thermophysical properties of materials at high temperatures.
Fast and economical process now available. New process applies rapidly solidified (RS) metal coatings to substrates. RS metals made directly from molten material. Have amorphous or microcrystalline structures and yield coatings having superior wear and corrosion resistance. Mixture of RS metal powder and peening particles sprayed from nozzle against surface coated. Powder and peening particles strike surface simultaneously, and impact bonds powder to surface as uniform coating. New process, which employs shot peening, is safe, fast, and inexpensive.
Peltier interface demarcation (PID) shown useful as aid in studying heat and mass transfer during growth of crystals from molten material. In PID, two dissimilar "metals" solid and liquid phases of same material. Current pulse passed through unidirectionally solidifying sample to create rapid Peltier thermal disturbance at liquid/solid interface. Disturbance, measured by thermocouple stationed along path of solidification at or near interface, provides information about position and shape of interface.
Thermal diffusivity of molten and solid mercury cadmium telluride measured with aid of new apparatus. Knowledge gained from such measurements help efforts to grow high-quality single crystals of this semiconductor for use in infrared detectors: Without knowledge of thermal diffusivity, difficult to control growth rate of solid from molten material.
System developed for studying use of laser beam for zone-refining semiconductors and metals. Specimen scanned with focused CO2 laser beam in such way that thin zone of molten material moves along specimen sweeps impurities with it. Zone-melting system comprises microcomputer, laser, electromechanical and optical components for beam control, vacuum chamber that holds specimen, and sensor for determining specimen temperature.
Various metals and metallic glass systems have bene processed into hollow spheres with sizes ranging from 3 mm to 440 microns in diameter. The technique for the formation of the large hollow spheres, in general, is based on the fluid-dynamic instability of a hollow annular jet. A refined technique has also been developed for microshell formation, in which discrete bubbles are injected into the stream of the molten material and individually 'flushed' out at a frequency related to the Rayleigh jet instability. The surfaces of those spheres of all sizes exhibit a range of contrasting solidification behaviors and characteristics. Metal shells of varying materials, sizes, aspect ratios, sphericity and concentricity have many useful and novel applications.
Dopant incorporated feed pellets to maintain required concentration. Technique of continuous replenishment of dopant in silicon melt helps ensure correct resistivity in solid silicon grown from melt. Technique used in dendritic-web growth process in which ribbon of silicon continously pulled from molten material. Providing uniform doping and resistivity in ribbon technique enables production of high-quality silicon ribbon at high yields for use in semiconductor devices.
Possible microgravity effects are explored in the combustion synthesis of ceramics and alloys from their constituent elements. Molten intermediates are typically present during the combustion process, thereby offering the chance for natural convection to take place. Numerical simulations suggest that the combustion front in concert with gravity may act as a partial zone-refinement mechanism which is attempting to sweep out porosity in the sample. Contrary to suggestions by dimensional analysis, no effects on the combustion rate are seen. An analytical model of the combustion velocity as a function of the gravitational field and the spreading rate of molten material gives the correct order of magnitude of the gravity effect as measured by centrifuge experiments.
Specimens of 440 C steel were rotated in a chamber pressurized with oxygen gas and heated with a 5-kW CO2 laser to determine the temperature required for autoignition to occur. Tests included exposures of static and rotating (25,000 rpm) specimens in oxygen pressurized to 5.51 MPa, and with focused laser fluences of more than 3.5 billion W/sq m. Specimen surface temperatures were monitored with a scanning infrared camera. Temperature measurement difficulties were experienced due to a problem with internal reflection inside the test chamber; however, posttest specimen examinations confirmed that surface melt (1371 C) was achieved in several tests. No sustained combustion was initiated in any rotating specimen. One static specimen was ignited. Results indicated that conditions necessary for autoignition of 440 C steel are more dependent on specimen geometry and available heat removal mechanisms. Sustained combustion occurred in the ignited static specimen with an estimated 130 C/sec cooling rate due to conduction. The rotating specimens could not sustain combustion due to a greater conductive/convective cooling rate of about 4000 C/sec and ejection of molten material. These results were applied to the Space Shuttle Main Engine (SSME) oxygen turbopump bearings to conclude that the LOX-cooled 440 C steel bearings cannot sustain combustion initiated by skidding friction.
Impactites (tagamites and suevites) from Popigai impact crater, whose diameter is about 100 km, are distributed over an area of 5000 sq km. The continuous sheet of suevite overlies the allogenic polymict breccia and partly authogenic breccia, and may also be observed in lenses or irregular bodies. The thickness of suevites in the central part of the crater is more than 100 m. Suevites may be distinguished by content of vitroclasts, lithoclasts, and crystalloclasts, by their dimensions, and by type of cementation, which reflects the facial settings of ejection of crushed and molten material, its sedimentation and lithification. Tagamites (impact melt rocks) are distributed on the surface predominantly in the western sector of the crater. The most characteristic are thick sheetlike bodies overlying the allogenic breccia and occurring in suevites where minor irregular bodies are widespread. The maximal thickness of separate tagamite sheets is up to 600 m. Tagamites, whose matrix is crystallized to a different degree, include fragments of minerals and gneiss blocks, among them shocked and thermally metamorphosed ones. Tagamite sheets have a complex inner structure; separate horizontal zones distinguish in crystallinity and fragment saturation. Differentiation in the impact melt in situ was not observed. The average chemical compositions of tagamites and suevites are similar, and correspond to the composition of biotite-garnet gneisses of the basement. According to the content of supplied Ir, Ni, and other siderophiles, impact melt was contaminated by 5 percent cosmic matter of collided body, probably ordinary chondrite. The total volume of remaining products of chilled impact melt is about 1750 cu km. Half this amount is represented by tagamite bodies. Though impact melt was in general well homogenized, the trend analysis showed that the concentric zonation is distribution of SiO2, MgO, and Na2O and the bandlike distribution of FeO and Al2O3 content testifies to a certain inheritance and heterogeneity in country rock composition laterally and vertically in the melting zone.
Apparatus grows high-quality single crystals of organic compounds by Czochralski method. In Czochralski process, growing crystal lifted from middle of molten material without touching walls. Because of low melting temperatures of organic crystals, glass vessels usable. Traditional method for inorganic semiconductors adapted to optically nonlinear organic materials.
The Cretaceous/Tertiary (K/T) boundary Chicxulub impact is the best preserved large impact in the geologic record. The Chicxulub crater has been buried with no apparent erosion of its intracrater deposits, and its ejecta blanket is known and is well preserved at hundreds of localities globally. Although most of the molten material ejected from the crater has been largely altered, a few localities still preserve tektite glass. Availability of intra- and extracrater impact products as well as plausible matches to the targeted rocks allows the comparison of compositions of the different classes of impact products to those of the impacted lithologies. Determination of trace-element compositions of the K/T tektites, Chicxulub melt rock, and the targeted Yucatan silicate basement and carbonate/evaporite lithologies have been made using instrumental neutron activation analysis (INAA) and inductively coupled plasma mass spectrometry (ICP-MS). Some sample splits were studied with both techniques to ensure that inter-laboratory variation was not significant or could be corrected. The concentration of a few major and minor elements was also checked against microprobe results. Radiochemical neutron activation analysis (RNAA) was used to determine Ir abundances in some samples.
This presentation consists of two parts: comments on the results of measurements on thermophysical properties based on the paper, 'Things Mother Never Taught Me (About Thermophysical Properties of Solids)' and results of thermophysical property measurements on selected solid and molten semiconductors and a proprietary superalloy. The first part may be considered as a tutorial for those involved in using or procuring thermophysical property data. The second part is presented as illustrations of what has been accomplished on molten materials at the Thermophysical Properties Research Laboratory (TPRL). The materials include Ge, PbTe, PbSnTe, HgCdTe and a superalloy.
The Isothermal Dendritic Growth Experiment (IDGE) flew on STS-62 to study the microscopic, tree-like structures (dendrites) that form within metals as they solidify from molten materials. The size, shape, and orientation of these dendrites affect the strength and usefulness of metals. Data from this experiment will be used to test and improve the mathematical models that support the industrial production of metals.
A numerical model of HgCdTe solidification was implemented using finite the element code FIDAP. Model verification was done using both experimental data and numerical test problems. The model was used to evaluate possible effects of double-diffusion convection in molten material, and microgravity level on concentration distribution in the solidified HgCdTe. Particular attention was paid to incorporation of HgCdTe phase diagram. It was found, that below a critical microgravity amplitude, the maximum convective velocity in the melt appears virtually independent on the microgravity vector orientation. Good agreement between predicted interface shape and an interface obtained experimentally by quenching was achieved. The results of numerical modeling are presented in the form of video film.