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NASA NTRS1999

The Isothermal Dendritic Growth Experiment (IDGE)

The Isothermal Dendritic Growth Experiment (IDGE) constituted a series of three NASA-supported microgravity experiments, all of which flew aboard the space shuttle, Columbia. This experimental space flight series was designed and operated to grow and record dendrite solidification in the absence of gravity-induced convective heat transfer, and thereby produce a wealth of benchmark-quality data for testing solidification scaling laws. The data and analysis performed on the dendritic growth speed and tip size in Succinontrie (SCN) demonstrates that although the theory yields predictions that are reasonably in agreement with experiment, there are significant discrepancies. However, some of these discrepancies can be explained by accurately describing the diffusion of heat. The key finding involves recognition that the actual three-dimensional shape of dendrites includes time-dependent side-branching and a tip region that is not a paraboloid of revolution. Thus, the role of heat transfer in dendritic growth is validated, with the caveat that a more realistic model of the dendrite then a paraboloid is needed to account for heat flow in an experimentally observed dendrite. We are currently conducting additional analysis to further confirm and demonstrate these conclusions. The data and analyses for the growth selection physics remain much less definitive. From the first flight, the data indicated that the selection parameter, sigma*, is not exactly a constant, but exhibits a slight dependence on the supercooling. Additional data from the second flight are being examined to investigate the selection of a unique dendrite speed, tip size and shape. The IDGE flight series is now complete. We are currently completing analyses and moving towards final data archiving. It is gratifying to see that the IDGE published results and archived data sets are being used actively by other scientists and engineers. In addition, we are also pleased to report that the techniques and IDGE hardware system that the authors developed with NASA, are being currently employed on both designated flight experiments, like EDSE, and on flight definition experiments, like TDSE.

Glicksman, Martin E.↗

NASA NTRS1999

Identification of Gravity-Related Effects on Crystal Growth From Melts With an Immiscibility Gap

This work involves an experimental-numerical approach to study the effects of natural and Marangoni convections on solidification of single crystals from a silicate melt with a liquid-liquid immiscibility gap. Industrial use of crystals grown from silicate melts is becoming increasingly important in electronic, optical, and high temperature structural applications. Even the simplest silicate systems like Al203-SiO2 have had, and will continue to have, a significant role in the development of traditional and advanced ceramics. A unique feature of crystals grown from the silicate systems is their outstanding linear electro-optic properties. They also exhibit exceptionally high optical rotativity. As a result, these crystals are attractive materials for dielectric, optical, and microwave applications. Experimental work in our laboratory has indicated that directional solidification of a single crystal mullite appears to be preceded by liquid-liquid phase separation in the melt. Disruption of the immiscible state results in crystallization of a two phase structure. There is also evidence that mixing in the melt caused by density-driven convection can significantly affect the stability of the immiscible liquid layers and result in poly-crystalline growth. On earth, the immiscible state has only been observed for small diameter crystals grown in float zone systems where natural convection is almost negligible. Therefore, it is anticipated that growth of large single crystals from silicate melts would benefit from microgravity conditions because of the reduction of the natural convective mixing. The main objective of this research is to determine the effects of transport processes on the phase separation in the melt during growth of a single crystal while addressing the following issues: (1) When do the immiscible layers form and are they real?; (2) What are the main physical characteristics of the immiscible liquids?; and (3) How mixing by natural or Marangoni convection affects the stability of the phase separated melt.

Kassemi, M.↗

NASA NTRS1997

Analysis of ripple formation in single crystal spot welds

Stationary spot welds have been made at the (001) surface of Fe-l5%Ni-15%Cr single crystals using a Gas Tungsten Arc (GTA). On the top surface of the spot welds, very regular and concentric ripples were observed after solidification by differential interference color microscopy. Their height (typically 1--5 micrometers and spacing, typically approximately 60 micrometers) decreased with the radius of the pool. These ripples were successfully accounted for in terms of capillary-wave theory using the fundamental mode frequency f(sub 0) given by the first zero of the zero-order Bessel function. The spacing d between the ripples was then equated to v(sub s)/f(sub 0), where v(sub s) is the solidification rate. From the measured ripple spacing, the velocity of the pool was deduced as a function of the radius, and this velocity was in good agreement with the results of a heat-flow simulation.

Rappaz, M.↗

NASA NTRS1998

A Study of Undercooling Behavior Of Immiscible Metal Alloys in the Absence of Crucible-Induced Nucleation

The purpose of this study is to investigate the question: Would eliminating the crucible eliminate the wall-induced nucleation of one of the liquid phases in an immiscible alloy and result in undercooling of the liquid into the metastable region thereby producing significant differences in the separation process and the microstructure upon solidification. Another primary objective of this research is to study systems with a metastable miscibility gap and to directly determine the metastable liquid miscibility gap by undercooling experiments. Nucleation and growth of droplets in these undercooled metallic liquid-liquid mixtures is also being studied. Results of this investigation indicate that containerless processing of immiscibles may not promote the undercooling of the single-phase liquid into the metastable region. Although no recalescence event was observed for this liquid-liquid transition, undercooling did occur across the miscibility gap for the solidification of the Ti phase that eventually separated.

Robinson, Michael B.↗

NASA NTRS1999

Double Diffusive Convection in Materials Processing

A great number of crystals grown in space are plagued by convective motions which contribute to structural flaws. The character of these instabilities is not well understood but is associated with density variations in the presence of residual gravity (g-jitter). As a specific example, past HgCdTe crystal growth space experiments by Lehoczky and co-workers indicate radial compositional asymmetry in the grown crystals. In the case of HgCdTe the rejected component into the melt upon solidification is HgTe which is denser than the melt. The space grown crystals indicate the presence of three dimensional flow with the heavier HgTe-rich material clearly aligned with the residual gravity (0.55-1.55 micro g) vector. This flow stems from double-diffusive convection, namely, thermal and solutal buoyancy driven flow in the melt. The study of double-diffusive convection is multi-faceted and rather vast. In our investigation, we seek to focus on one specific aspect of this discipline that is of direct relevance to materials processing especially crystal growth, namely, the side ways heating regime. This problem has been widely studied, both experimentally and numerically, in the context of solar ponds wherein the system is characterized by a linear salt (solutal) gradient with an imposed lateral temperature gradient. The induced flow instabilities arise from the wide disparity between the fluid thermal diffusivity and the solute diffusivity. The extension of the analysis to practical crystal growth applications has however not been rigorously made and understood. One subtle but important difference in crystal growth systems is the fact that die system solute gradient is non-linear (typically exponential). Besides, the crystal growth problem has the added complexities of solidification, both lateral and longitudinal thermal gradients and segregation phenomena in systems where binary and ternary compounds are being grown. This paper treats the side ways heating problem alone in a model fluid system. Results from detailed numerical calculations, mainly two dimensional are provided. The interactions between a non-linear solute gradient and an imposed transverse thermal gradient are investigated. The buoyancy effects are treated in the traditional Boussinesq approximation and also in a more complete density formulation to address recent concerns of the first approach especially in simulations of the system response in a reduced gravity environment. Detailed flow, temperature and solute field plots along with heat and mass transfer results are presented in the paper. Implications to practical crystal growth systems as discerned from the modeling results are also explored and reported.

Ramachandra, Narayanan↗

NASA NTRS1998

Particle Engulfment and Pushing by Solidifying Interfaces LMS Mission Results

Results of the directional solidification experiments on Particle Engulfment and Pushing by Solidifying Interfaces (PEP) conducted on the space shuttle Columbia are reported. The experiment was manifested as part of The Life and Microgravity Science Mission. Two pure aluminum (99.999%) 9 mm cylindrical rods, loaded with about 2 vol.% 500 microns diameter zirconia particles were melted and directionally solidified in the microgravity (micro-g) environment of the shuttle. The particles were non-reactive with the matrices within the temperature range of interest. The experiments were conducted such as to insure a planar solid/liquid interface during solidification. Two different cartridge - crucible - sample designs were used: a spring-piston and expansion void. Both resulted in sound samples. Samples were evaluated post-flight for soundness by X-ray computer tomography (XCT).

Juretzko, Frank R.↗

NASA NTRS1998

Particle Engulfment and Pushing by Solidifying Interfaces: Micro-Gravity Experiments and Theoretical Analysis - Pt. 2

Results of the directional solidification experiments on Particle Engulfment and Pushing by Solidifying Interfaces (PEP) conducted on the space shuttle Columbia during the Life and Microgravity Science Mission are reported. Two pure aluminum (99.999%) 9 mm cylindrical rods, loaded with about 2 vol.% 500 micrometers diameter zirconia particles were melted and resolidified in the microgravity (microg) environment of the shuttle. One sample was processed at step-wise increased solidification velocity, while the other at step-wise decreased velocity. It was found that a pushing-to-engulfment transition (PET) occurred in the velocity range of 0.5 to 1 micrometers. This is smaller than the ground PET velocity of 1.9 to 2.4 micrometers. This demonstrates that natural convection increases the critical velocity. A previously proposed analytical model for PEP was further developed. A major effort to identify and produce data for the surface energy of various interfaces required for calculation was undertaken. The predicted critical velocity for PET was of 0.775 micrometers/s.

Stefanescu, Doru M.↗

NASA NTRS1998

Acquisition and Early Losses of Rare Gases from the Deep Earth

Direct observations show that the deep Earth contains rare gases of solar composition distinct from those in the atmosphere. We examine the implications of mantle rare gas characteristics on acquisition of rare gases from the solar nebula and subsequent losses due to a large impact. Deep mantle rare gas concentrations and isotopic compositions can be obtained from a model of transport and distribution of mantle rare gases. This model assumes the lower mantle closed early, while the upper mantle is open to subduction from the atmosphere and mass transfer from the lower mantle. Constraints are derived that can be incorporated into models for terrestrial volatile acquisition: (1) Calculated lower-mantle Xe-isotopic ratios indicate that the fraction of radiogenic Xe produced by I-129 and Pu-244 during the first about 10(exp 8) yr was lost, a conclusion also drawn for atmospheric Xe. Thus, either the Earth was made from materials that had lost >99% of rare gases about (0.7-2) x 10(exp 8) yr after the solar system formed, or gases were then lost from the fully formed Earth. (2) Concentrations of 3He and 20Ne in the lower mantle were established after these losses. (3) Neon-isotopic data indicates that mantle Ne has solar composition. The model allows for solar Ar/Ne and Xe/Ne in the lower mantle if a dominant fraction of upper mantle Ar and Xe are subduction-derived. If Earth formed in the presence of the solar nebula, it could have been melted by accretional energy and the blanketing effect of a massive, nebula-derived atmosphere. Gases from this atmosphere would have been sequestered within the molten Earth by dissolution at the surface and downward mixing. It was found that too much Ne would be dissolved in the Earth unless the atmosphere began to escape when the Earth was only partially assembled. Here we consider conditions required to initially dissolve sufficient rare gases to account for the present lower mantle concentrations after subsequent losses at 10(exp 8) yr. It is assumed that equilibration of the atmosphere with a thoroughly molten mantle was rapid, so that initial abundances of gases retained in any mantle layer reflected surface conditions when the layer solidified. For subsequent gas loss of 99.5% and typical solubility coefficients, a total pressure of 100 atm was required for an atmosphere of solar composition. Calculations of the pressure at the base of a primordial atmosphere indicate that this value might be exceeded by an order of magnitude or more for an atmosphere supported by accretional energy. Surface temperatures of about 4000 K would have been produced, probably high enough to melt the deep mantle. Initial distributions of retained rare gases would then be determined by the history of surface pressure and temperature during mantle cooling and solidification, i.e., the coupled cooling of Earth and atmosphere. The Earth's thermal state was determined by its surface temperature and the efficiency of convection in the molten mantle, estimated to be sufficient to maintain an adiabatic gradient. Because the melting curve is steeper than the adiabat, solidification of the mantle proceeded outward from the interior. Incorporation of atmospheric gases in the mantle therefore occurred over a range in surface temperature of a few thousand degrees Kelvin. The thermal state of the atmosphere was controlled by total luminosity of the Earth (energy) released by accreting planetesimals and the cooling Earth), nebular temperature and pressure, and atmospheric opacity. The energy released by accretion declined with time as did nebular pressure. Analytical solutions for an idealized (constant opacity radiative atmosphere show that declining energy sources under constant nebular conditions result in slowly diminishing surface temperature but dramatically increasing surface pressure. For such an atmosphere with declining nebular pressure but constant total luminosity, surface pressure decreases gradually with decreasing temperaure. A decline in accretion luminosity might be compensated by energy released as the mantle cools for about 10(exp 5) year, after which luminosity must decline. The total complement of dissolved rare gases will depend on the particular evolutionary path determined by the declining accretional luminosity, the Earth thermal history, removal of the nebula, and opacity variations of the atmosphere. Models for these coupled evolutionary histories for Earth's acquisition of nebular-derived noble gases are in progress. The later losses required at about 10(exp 8) yr (depleting the interior concentrations of the sequestered solar gases by a factor of > 100) were presumably related to the major impact in which the Moon formed.

Porcelli, D.↗

NASA NTRS1999

Numerical Simulations of Crystal Growth of an Alloy Under Microgravity Conditions

The directional solidification of a dilute binary alloy (Bi-1.0 at.%Sn)is investigated. Results are obtained at a gravity level of I pg. Computations are performed in two dimensions with a fixed, non-uniform grid. The simulation involves a solution of the species concentration equation (modified to account for solute rejection at the interface) and energy equation (modified to account for phase-change) for both the solid and liquid phases, in addition to the constitutive equations for describing convective flow in the melt. The effects of conductive heat transfer in the ampoule and in a capillary tube in the sample are included. To gauge the effects of including this growth capillary tube in the apparatus, simulations both with and without the capillary tube are presented and compared. Fully transient simulations have been performed; no simplifying steady-state approximations are used, however, the influence of solute on the melting temperature at the interface is not included. Both thermal and solutal convective cells are seen to form. Convective velocities are significantly damped inside the capillary, causing less segregation due to convection. As solidification proceeds beyond the capillary tube, longitudinal segregation arises as a result of the change in cross-sectional area of solidifying material. The magnitudes of the velocities in this cell increase significantly once the solid/liquid front passes beyond the end of the capillary tube; this causes a corresponding increase in the level of radial solute segregation in the solidified material.

Simpson, James E.↗

NASA NTRS2000

The Life Cycle Application of Intelligent Software Modeling for the First Materials Science Research Rack

Marshall Space Flight Center (MSFC) has been funding development of intelligent software models to benefit payload ground operations for nearly a decade. Experience gained from simulator development and real-time monitoring and control is being applied to engineering design, testing, and operation of the First Material Science Research Rack (MSRR-1). MSRR-1 is the first rack in a suite of three racks comprising the Materials Science Research Facility (MSRF) which will operate on the International Space Station (ISS). The MSRF will accommodate advanced microgravity investigations in areas such as the fields of solidification of metals and alloys, thermo-physical properties of polymers, crystal growth studies of semiconductor materials, and research in ceramics and glasses. The MSRR-1 is a joint venture between NASA and the European Space Agency (ESA) to study the behavior of different materials during high temperature processing in a low gravity environment. The planned MSRR-1 mission duration is five (5) years on-orbit and the total design life is ten (IO) years. The MSRR-1 launch is scheduled on the third Utilization Flight (UF-3) to ISS, currently in February of 2003). The objective of MSRR-1 is to provide an early capability on the ISS to conduct material science, materials technology, and space product research investigations in microgravity. It will provide a modular, multi-user facility for microgravity research in materials crystal growth and solidification. An intelligent software model of MSRR-1 is under development and will serve multiple purposes to support the engineering analysis, testing, training, and operational phases of the MSRR-1 life cycle development. The G2 real-time expert system software environment developed by Gensym Corporation was selected as the intelligent system shell for this development work based on past experience gained and the effectiveness of the programming environment. Our approach of multi- uses of the simulation model and its intuitive graphics capabilities is providing a concurrent engineering environment for rapid prototyping and development. Operational schematics of the MSRR-1 electrical, thermal control, vacuum access, and gas supply systems, and furnace inserts are represented graphically in the environment. Logic to represent first order engineering calculations is coded into the knowledge base to simulate the operational behavior of the MSRR-1 systems. An example of engineering data provided includes electrical currents, voltages, operational power, temperatures, thermal fluid flow rates. pressures, and component status indications. These type of data are calculated and displayed at appropriate instrumentation points, and the schematics are animated to reflect the simulated operational status of the MSRR-1. The software control functions are also simulated to represent appropriate operational behavior based on automated control and response to commands received by the crew or ground controllers. The first benefit of this simulation environment is being realized in the high fidelity engineering analysis results from the electrical power system G2 model. Secondly, the MSRR-1 simulation model will be embedded with a hardware mock-up of the MSRR-1 to provide crew training on MSRR-1 integrated payload operations. G2 gateway code will output the simulated instrumentation values, termed as telemetry, in a flight-like data stream so that the crew has realistic and accurate simulated MSRR-1 data on the flight displays which will be designed for crew use. The simulation will also respond appropriately to crew or ground initiated commands, which will be part of normal facility operations. A third use of the G2 model is being planned; the MSRR-1 simulation will be integrated with additional software code as part of the test configuration of the primary onboard computer, or Master Controller, for MSRR-1. We will take advantage of the G2 capability to simulate the flight like data stream to test flight software responses and behavior. A fourth use of the G2 model will be to train the Ground Support Personnel that will monitor the MSRR-1 systems and payloads while they are operating aboard the ISS. The intuitive, schematic based environment will provide an excellent foundation for personnel to understand the integrated configuration and operation of the MSRR-1, and the anticipated telemetry feedback based on operational modes of the equipment. Expert monitoring features will be enhanced to provide a smart monitoring environment for the operators. These features include: (1) Animated, intuitive schematic-based displays which reflect telemetry values, (1) Real-time plotting of simulated or incoming sensor values, (3) High/Low exception monitoring for analog data, (4) Expected state monitoring for discrete data, (5) Data trending, (6) Automated malfunction procedure execution to diagnose problems, (7) Look ahead capability to planned MSRR-1 activities in the onboard timeline. And finally, the logic to calculate telemetry values will be deactivated, and the same environment will interface to the incoming data for the real-time telemetry stream to schematically represent the onboard hardware configuration. G2 will be the foundation for the real-time monitoring and control environment. In summary, our MSRR-1 simulation model spans many elements of the life cycle development of this project: Engineering Analysis, Test and Checkout, Training of Crew and Ground Personnel, and Real-time monitoring and control. By utilizing the unique features afforded by an expert system development environment, we have been able to synergize a powerful tool capable of addressing our project needs at every phase of project development.

Rice, Amanda↗

NASA NTRS2000

Effects of Melt Convection and Solid Transport on Macrosegregation and Grain Structure in Equiaxed Al-Cu Alloys

Macrosegregation in metal casting can be caused by thermal and solutal melt convection, and the transport of unattached solid crystals resulting from nucleation in the bulk liquid or dendrite fragmentation. To develop a comprehensive numerical model for the casting of alloys, an experimental study has been conducted to generate benchmark data with which such a solidification model could be tested. The objectives were: (1) experimentally study the effects of solid transport and thermosolutal convection on macrosegregation and grain size; and (2) provide a complete set of boundary conditions temperature data, segregation data, and grain size data - to validate numerical models. Through the control of end cooling and side wall heating, radial temperature gradients in the sample and furnace were minimized. Thus the vertical crucible wall was adiabatic. Samples at room temperature were 24 cc and 95 mm long. The alloys used were Al-1 wt. pct. Cu, and Al- 10 wt. pct. Cu; the starting point for solidification was isothermal at 710 and 685 C respectively. To induce an equiaxed structure various amounts of the grain refiner TiB2 were added. Samples were either cooled from the top, or the bottom. Several trends in the data stand out. In attempting to model these experiments, concentrating on these trends or differences may be beneficial.

Rerko, Rodney S.↗

NASA NTRS2000

Suppression/Reversal of Natural Convection by Exploiting the Temperature/Composition Dependence of Magnetic Susceptibility

Natural convection, driven by temperature-or concentration gradients or both, is an inherent phenomenon during solidification of materials on Earth. This convection has practical consequences (e.g effecting macrosegregation) but also renders difficult the scientific examination of diffusive/conductive phenomena during solidification. It is possible to halt, or even reverse, natural convection by exploiting the variation (with temperature, for example) of the susceptibility of a material. If the material is placed in a vertical magnetic field gradient, a buoyancy force of magnetic origin arises and, at a critical field gradient, can balance the normal buoyancy forces to halt convection. At higher field gradients the convection can be reversed. The effect has been demonstrated in experiments at Marshall Space Flight Center where flow was measured by PIV in MnCl2 solution in a superconducting magnet. In auxiliary experiments the field in the magnet and the properties of the solution were measured. Computations of the natural convection, its halting and reversal, using the commercial software FLUENT were in good agreement with the measurements.

Seybert, C. D.↗

NASA NTRS2000

Characterizing the Use of Ultrasonic Energy in Promoting Uniform Composite Growth in Immiscible Alloys

The results of experimental investigation and mathematical modeling for immiscible alloys subjected to ultrasonic influence are presented. It is known that in inoculated light alloy melts, ultrasonic treatment creates a new type of cast structure with extremely fine grains of uniform composition. This effect is produced across a wide range of freezing rates and technologies. However, it has not been demonstrated that the process can be successfully applied during controlled directional solidification processing. In this work we present the results from a set of directional solidification experiments and suggest describing the droplet size versus ultrasonic frequency and amplitude using an energy approach, followed with a more detailed analysis through numerical modeling of the ultrasonic field.

Grugel, Richard N.↗

NASA NTRS2000

A Solid Case for Microgravity Processing

Solidification of metals, particularly alloys, is a complicated process. At some sufficiently high temperature, the components comprising an alloy fully mix, producing a single homogeneous liquid. Unfortunately, after this liquid is cast into a mold and allowed to freeze, the resulting solid is usually very inhomogeneous. In most cases the first solid to "freeze out" of the liquid has a composition very close to one of the pure metals. This initially solidifying metal usually comprises microscopic, pine-tree shaped components, collectively referred to as a dendritic array, whose distribution, alignment, and scale directly influence a materials strength and docility. During dendrite growth the adjacent liquid becomes enriched, and consequently, solidifies a much lower temperature and considerably later time. Thus, in the course of solidification, both the solid and the enriched liquid can have compositions (and local temperatures) significantly different from those of the bulk liquid. Different compositions and temperatures imply different densities that, in Earth's gravity, induce motion in the liquid. Such motion promotes formation of a casting that is denser at the bottom and lighter at the top. This condition known as macrosegregation, precludes optimized, uniform material properties.

Grugel, Richard N.↗

NASA NTRS2000

Numerical Calculation of the Drag Force Acting on a Solid Particle Pushed by a Solid/Liquid Interface

The distribution of insoluble particles in a metal casting depends primarily on the interaction of the particles with the solid/liquid interface (SLI) during the solidification process. The balance of the forces acting on the particle essentially determines whether a particle will be engulfed or pushed by the SLI. An important component of this force balance is the drag force generated by the particle motion in front of the SLI. Previously developed mathematical models for particle/SLI interaction made use of steady-state solutions of this force provided by the lubrication theory. However, our numerical model based on the SLI tracking approach shows that the steady-state approach is inappropriate to model the interaction process and that at steady-state the theoretical solution underestimates the drag force. It was found that regression analysis of steady-state numerical solutions for cylindrical particles moving normal to a flat SLI gives a relationship of the form: Abstract The distribution of insoluble particles in a metal casting depends primarily on the interaction of the particles with the solid/liquid interface (SLI) during the solidification process. The balance of the forces acting on the particle essentially determines whether a particle will be engulfed or pushed by the SLI. An important component of this force balance is the drag force generated by the particle motion in front of the SLI. Previously developed mathematical models for particle/SLI interaction made use of steady-state solutions of this force provided by the lubrication theory. However, our numerical model based on the SLI tracking approach shows that the steady-state approach is inappropriate to model the interaction process and that at steady-state the theoretical solution underestimates the drag force. It was found that regression analysis of steady-state numerical solutions for cylindrical particles moving normal to a flat SLI gives a relationship of the form: F(sub D, sup num) =sqoare root of 3(pi)(eta)V(sub p)(R(sub p)/d)(sup 10(gamma)/3). This is to compared to the solution provided by the lubrication theory: F(sub D), sup theor) = 3 square root of 2(pi)(eta)V(sub p)(R(sub p)/d)(sub 3/2), where F(sub D) is the drag force, eta is the dynamic viscosity of the fluid, V(sub p) is the particle velocity, R(sub p) is the particle radius, gamma is Euler's constant (gamma approx. = 0.577), and d is the width of the gap between the particle and the SLI. The domain on which the equations proposed by the lubrication theory are relevant is clearly identified in the paper. The numerical model was then validated against the classical lubrication theory within the domain of its validity.

Catalina, Adrian V.↗

NASA NTRS2000

Characterizing the Use of Ultrasonic Energy in Promoting Uniform Microstructural Dispersions in Immiscible Mixtures

Gravity driven separation and preferential wetting precludes uniform microstructural distributions during solidification processing of immiscible, liquid-liquid mixtures. Historically, it is, however, established that liquid/liquid suspensions can be established and maintained by utilizing ultrasound. Following a brief introduction the results of experiments on immiscible mixtures subjected to ultrasonic energy during solidification processing will be compared and evaluated in view of a recently developed mathematical model. The presentation continues by discussion of scaling the model to commercial viability and concludes with the implications of such processing in a microgravity environment.

Grugel, R. N.↗

NASA NTRS2001

Characterizing the Use of Ultrasonic Energy in Promoting Uniform Microstructural Dispersions in Immiscible Mixtures

Grugel, R. N.↗

NASA NTRS2001

Numerical Modeling of Liquid-Vapor Phase Change

We implemented a two- and three-dimensional finite difference/front tracking technique to solve liquid-vapor phase change problems. The mathematical and the numerical features of the method were explained in great detail in our previous reports, Briefly, we used a single formula representation which incorporated jump conditions into the governing equations. The interfacial terms were distributed as singular terms using delta functions so that the governing equations would be the same as conventional conservation equations away from the interface and in the vicinity of the interface they would provide correct jump conditions. We used a fixed staggered grid to discretize these equations and an unstructured grid to explicitly track the front. While in two dimensions the front was simply a connection of small line segments, in three dimensions it was represented by a connection of small triangular elements. The equations were written in conservative forms and during the course of computations we used regriding to control the size of the elements of the unstructured grid. Moreover, we implemented a coalescence in two dimensions which allowed the merging of different fronts or two segments of the same front when they were sufficiently close. We used our code to study thermocapillary migration of bubbles, burst of bubbles at a free surface, buoyancy-driven interactions of bubbles, evaporation of drops, rapid evaporation of an interface, planar solidification of an undercooled melt, dendritic solidification, and a host of other problems cited in the reference.

Esmaeeli, Asghar↗