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Glass frit can be mixed with consistently reproducible properties even from different batches of glass frit using technique to measure one quantity that determines integrated properties of frit for combination with given liquid.
Filter disks made of glass frit have been found to be effective as means of high-throughput collection of metal oxide particles, ranging in size from a few to a few hundred nanometers, produced in gas-phase condensation reactors. In a typical application, a filter is placed downstream of the reactor and a valve is used to regulate the flow of reactor exhaust through the filter. The exhaust stream includes a carrier gas, particles, byproducts, and unreacted particle-precursor gas. The filter selectively traps the particles while allowing the carrier gas, the byproducts, and, in some cases, the unreacted precursor, to flow through unaffected. Although the pores in the filters are much larger than the particles, the particles are nevertheless trapped to a high degree: Anecdotal information from an experiment indicates that 6-nm-diameter particles of MnO2 were trapped with greater than 99-percent effectiveness by a filtering device comprising a glass-frit disk having pores 70 to 100 micrometer wide immobilized in an 8-cm-diameter glass tube equipped with a simple twist valve at its downstream end.
The recent availability of step‐edge, frit‐disc crucible sets (generally sold as Canfield Crucible Sets or CCS) has led to multiple innovations associated with the group's use of solution growth. The use of CCS allows for the clean separation of liquid from solid phases during the growth process. This clean separation enables the reuse of the decanted liquid, either allowing for simple, economic, savings associated with recycling expensive precursor elements or allowing for the fractionation of a growth into multiple, small steps, revealing the progression of multiple solidifications. Clean separation of liquid from solid phases also allows for the determination of the liquidus line (or surface) and the creation, or correction, of composition–temperature phase diagrams. The reuse of clean decanted liquid has also allowed to prepare liquids ideally suited for the growth of large single crystals of specific phases by tuning the composition of the melt to the optimal composition for growth of the desired phase, often with reduced nucleation sites. Finally, it is discussed how solution growth and CCS use can be harnessed to provide a plethora of composition–temperature data points defining liquidus lines or surfaces with differing degrees of precision to either test or anchor artificial intelligence and/or machine‐learning‐based attempts to augment and extend the limited experimentally determined database.
The achievement of more compact and efficient power plants for aircraft is dependent, among other factors, on the perfection of heat-resisting materials that are superior to those in current use. Molybdenum is one of the high-melting metals (melting point, 4750 F). It is fairly abundant and also can be worked into many of the shapes required in modern power plants. To permit its widespread use at elevated temperatures, however, some means must first be found to prevent its rapid oxidation. The application of a protective coating is one method that might be used to achieve this goal. In the present work, a number of chromium-frit-type coatings were studied. These were bonded to molybdenum specimens by firing in controlled atmospheres to temperatures in the range of 2400 to 2700 F.
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A laboratory investigation was conducted to determine the physical and microwave properties of ocean foam. Special foam generators were designed and fabricated, using porous glass sheets, known as glass frits, as the principal element. The glass frit was sealed into a water-tight vertical box, a few centimeters from the bottom. Compressed air, applied to the lower chamber, created ocean foam from sea water lying on the frit. Foam heights of 30 cm were readily achieved, with relatively low air pressures. Special photographic techniques and analytical procedures were employed to determine foam bubble size distributions. In addition, the percentage water content of ocean foam was determined with the aid of a particulate sampling procedure. A glass frit foam generator, with pore diameters in the range 70 - 100 micrometers, produced foam with bubble distributions very similar to those found on the surface of natural ocean foam patches.
A computational fluid dynamics model with porosity and permeability formulations in the transport equations has been developed to study the concept of nuclear thermal propulsion through the analysis of a pulsed irradiation of a particle bed element (PIPE). The numerical model is a time-accurate pressure-based formulation. An adaptive upwind scheme is employed for spatial discretization. The upwind scheme is based on second- and fourth-order central differencing with adaptive artificial dissipation. Multiblocked porosity regions have been formulated to model the cold frit, particle bed, and hot frit. Multiblocked permeability regions have been formulated to describe the flow shaping effect from the thickness-varying cold frit. Computational results for several zero-power density PIPEs and an elevated-particle-temperature PIPE are presented. The implications of the computational results are discussed.
The particle bed reactor nuclear rocket concept consists of fuel particles (in this case (U,Zr)C with an outer coat of zirconium carbide). These particles are packed in an annular bed surrounded by two frits (porous tubes) forming a fuel element; the outer one being a cold frit, the inner one being a hot frit. The fuel element are cooled by hydrogen passing in through the moderator. These elements are assembled in a reactor assembly in a hexagonal pattern. The reactor can be either reflected or not, depending on the design, and either 19 or 37 elements, are used. Propellant enters in the top, passes through the moderator fuel element and out through the nozzle. Beryllium used for the moderator in this particular design to withstand the high radiation exposure implied by the long run times.
The particle-bed core offers mitigation of some of the problems of solid-core nuclear rocket reactors. Dividing the fuel elements into small spherical particles contained in a cylindrical bed through which the propellant flows radially, may reduce the thermal stress in the fuel elements, allowing higher propellant temperatures to be reached. The high temperature regions of the reactor are confined to the interior of cylindrical fuel assemblies, so most of the reactor can be relatively cool. This enables the use of structural and moderating materials which reduce the minimum critical size and mass of the reactor. One of the unresolved questions about this concept is whether the flow through the particle-bed will be well behaved, or will be subject to destructive flow instabilities. Most of the recent analyses of the stability of the particle-bed reactor have been extensions of the approach of Bussard and Delauer, where the bed is essentially treated as an array of parallel passages, so that the mass flow is continuous from inlet to outlet through any one passage. A more general three dimensional model of the bed is adopted, in which the fluid has mobility in three dimensions. Comparison of results of the earlier approach to the present one shows that the former does not accurately represent the stability at low Re. The more complete model presented should be capable of meeting this deficiency while accurately representing the effects of the cold and hot frits, and of heat conduction and radiation in the particle-bed. It can be extended to apply to the cylindrical geometry of particle-bed reactors without difficulty. From the exemplary calculations which were carried out, it can be concluded that a particle-bed without a cold frit would be subject to instability if operated at the high temperatures desired for nuclear rockets, and at power densities below about 4 megawatts per liter. Since the desired power density is about 40 megawatts per liter, it can be concluded that operation at design exit temperature but at reduced power could be hazardous for such a reactor. But the calculations also show that an appropriate cold frit could very likely cure the instability. More definite conclusions must await calculations for specific designs.
A three-dimensional model of the stability of the particle-bed reactor is presented, in which the fluid has mobility in three dimensions. The model accurately represents the stability at low Re numbers as well as the effects of the cold and hot frits and of the heat conduction and radiation in the particle bed. The model can be easily extended to apply to the cylindrical geometry of particle-bed reactors. Exemplary calculations are carried out, showing that a particle bed without a cold frit would be subject to instability if operated at the high-temperature ratios used for nuclear rockets and at power densities below about 4 MW/l; since the desired power density for such a reactor is about 40 MW/l, the operation at design exit temperature but at reduced power could be hazardous. Calculations show however that it might be possible to remove the instability problem by appropriate combinations of cold and hot frits.
Thermal-hydraulics design and analyses of the Pellet Bed Reactor for nuclear thermal propulsion are performed using the nuclear propulsion thermal-hydraulic analysis model to determine the 2D steady-state temperature, pressure, and flow fields in the core and optimize the orificing in the hot-frit to avoid hot spots in the core at full power operation. Results show that by properly adjusting the axial porosity profile in the hot frit, hot spots in the core can be essentially eliminated during full power operation. This important accomplishment is achieved at the expense of slightly larger pressure losses in the core because of flow restriction at the hot frit. However, the overall pressure losses is only about 11 percent of the propellant inlet pressure.
A versatile and simple approach to the design and fabrication of curved-focal-plane arrays of silicon-based photodetectors is being developed. This approach is an alternative to the one described in "Curved Focal-Plane Arrays Using Back- Illuminated High-Purity Photodetectors" (NPO-30566), NASA Tech Briefs, Vol. 27, No. 10 (October 2003), page 10a. As in the cited prior article, the basic idea is to improve the performance of an imaging instrument and simplify the optics needed to obtain a given level of performance by making an image sensor (in this case, an array of photodetectors) conform to a curved focal surface, instead of designing the optics to project an image onto a flat focal surface. There is biological precedent for curved-focal-surface designs: retinas - the image sensors in eyes - conform to the naturally curved focal surfaces of eye lenses. The present approach is applicable to both front-side- and back-side-illuminated, membrane photodetector arrays and is being demonstrated on charge-coupled devices (CCDs). The very-large scale integrated (VLSI) circuitry of such a CCD or other array is fabricated on the front side of a silicon substrate, then the CCD substrate is attached temporarily to a second substrate for mechanical support, then material is removed from the back to obtain the CCD membrane, which typically has a thickness between 10 and 20 m. In the case of a CCD designed to operate in back-surface illumination, delta doping can be performed after thinning to enhance the sensitivity. This approach is independent of the design and method of fabrication of the front-side VLSI circuitry and does not involve any processing of a curved silicon substrate. In this approach, a third substrate would be prepared by polishing one of its surfaces to a required focal-surface curvature. A CCD membrane fabricated as described above would be pressed against, deformed into conformity with, and bonded to, the curved surface. The technique used to press and bond the CCD membrane would depend on the nature of the supporting material (see figure). For example, if the third substrate were made of quartz frit, the substrate would be prepared by suffusing it with epoxy. Then one would take advantage of the porosity of the frit by applying a partial vacuum to the opposite surface of the frit, causing atmospheric pressure to push the CCD membrane against the curved surface. The curing of the epoxy would bond the CCD membrane to the curved surface. Alternatively, if the third substrate were made of a nonporous material, the curved substrate surface would be prepared by coating it with a wax or an uncured epoxy. The CCD membrane would be pressed against the coated, curved surface by use of a suitably pressurized balloon. The CCD membrane would then become bonded to the curved surface by curing of the epoxy or freezing of the wax.
A white porcelain enamel coating was developed for application to high temperature metallic alloy substrates on spacecraft. The coating consists of an optically opacifying zirconia pigment, a lithia-zirconia-silica frit, and an inorganic pigment dispersant. The coating is fired at 1000 to 1150 C to form the enamel. The coating has a solar absorptance of 0.22 and a total normal emittance of 0.82 for a 0.017 cm thick coating. The coating exhibits excellent adhesion, cleanability, and integrity and is thermal shock resistant to 900 C. Capability to coat large panels has been demonstrated by successful coating of 30 cm x 30 cm Hastelloy X alloy panels. Preliminary development of low temperature enamels for application to aluminum and titanium alloy substrates was initiated. It was determined that both leaded and leadless frits were feasible when applied with appropriate mill fluxes. Indications were that opacification could be achieved at firing temperatures below 540 C for extended periods of time.
The development and evaluation of materials for potential application as heat exchanger structures in automotive gas turbine engines is discussed. Test specimens in the form of small monolithic bars were evaluated for thermal expansion and dimensional stability before and after exposure to sea salt and sulfuric acid, followed by short and long term cycling at temperatures up to 1200 C. The material finally selected, GE-7808, consists of the oxides, ZrO2-MgO-Al2O3-S1O2, and is described generically as ZrMAS. The original version was based on a commercially available cordierite (MAS) frit. However, a clay/talc mixture was demonstrated to be a satisfactory very low cost source of the cordierite (MAS) phase. Several full size honeycomb regenerator cores, about 10.2 cm thick and 55 cm diameter were fabricated from both the frit and mineral versions of GE-7808. The honeycomb cells in these cores had rectangular dimensions of about 0.5 mm x 2.5 mm and a wall thickness of approximately 0.2 mm. The test data show that GE-7808 is significantly more stable at 1100 C in the presence of sodium than the aluminosilicate reference materials. In addition, thermal exposure up to 1100 C, with and without sodium present, results in essentially no change in thermal expansion of GE-7808.
The operations of solar cell manufacture are briefly examined. The formation of reliable, ohmic, low-loss, and low-cost metal contacts on solar cells is a critical process step in cell manufacturing. In a commonly used process, low-cost metallization is achieved by screen printing a metal powder-glass frit ink on the surface of the Si surface and the conductive metal powder. A technique utilizing a molybdenum-tin alloy for the metal contacts appears to lower the cost of materials and to reduce process complexity. The ink used in this system is formulated from MoO3 with Sn powder and a trace amount of titanium resonate. Resistive losses of the resulting contacts are low because the ink contains no frit. The MoO3 is finally melted and reduced in forming gas (N2+H2) to Mo metal. The resulting Mo is highly reactive which facilitates the Mo-Si bonding.
Printed nickel overplated with copper and applied on top of a predeposited silicon nitride antireflective coating system for metallizing solar cells was analyzed. The ESL D and E paste formulations, and the new formulations F, G, H, and D-1 were evaluated. The nickel thick films were tested after firing for stability in the cleaning and plating solutions used in the Vanguard-Pacific brush plating process. It was found that the films are very sensitive to the leaning and alkaline copper solutions. Less sensitivity was displayed to the neutral copper solution. Microscopic and SEM observations show segregation of frit at the silicon nitride thick film interface with loose frit residues after lifting off plated grid lines.
Solar cells were made with a variety of base metal screen printing inks applied over silicon nitride AR coating and copper electroplated. Fritted and fritless nickel and fritless tin base printing inks were evaluated. Conversion efficiencies as high as 9% were observed with fritted nickel ink contacts, however, curve shapes were generally poor, reflecting high series resistance. Problems encountered in addition to high series reistance included loss of adhesion of the nickel contacts during plating and poor adhesion, oxidation and inferior curve shapes with the tin base contacts.
Rate of evaporation adjusted to produce larger crystals. Device helps to control vapor pressure of water and other solvents in vicinity of hanging drop of solution containing dissolved enzyme protein. Well of porous frit (sintered glass) holds solution in proximity to drop of solution containing protein or enzyme. Vapor from solution in frit controls evaporation of solvent from drop to control precipitation of protein or enzyme. With device, rate of nucleation limited to decrease number and increase size (and perhaps quality) of crystals - large crystals of higher quality needed for x-ray diffraction studies of macromolecules.