William F. Kaukler

Real-Time X-Ray Transmission Microscopy of Solidifying Al-In Alloys

Real-time observations of transparent analog materials have provided insight, yet the results of these observations are not necessarily representative of opaque metallic systems. In order to study the detailed dynamics of the solidification process, we develop the technologies needed for real-time Xray microscopy of solidifying metallic systems, which has not previously been feasible with the necessary resolution, speed, and contrast. In initial studies of Al-ln monotectic alloys unidirectionally solidified in an X-ray transparent furnace,in situ records of the evolution of interface morphologies, interfacial solute accumulation, and formation of the monotectic droplets were obtained for the first time: A radiomicrograph of Al-30In grown during aircraft parabolic maneuvers is presented, showing the volumetric phase distribution in this specimen. The benefits of using X-ray microscopy for postsolidification metallography include ease of specimen preparation, increased sensitivity, and three-dimensional analysis of phase distribution. Imaging of the solute boundary layer revealed that the isoconcentration lines are not parallel (as is often assumed) to the growth interface. Striations in the solidified crystal did not accurately decorate the interface position and shape. The monotectic composition alloy under some conditions grew in an uncoupled manner.

Laser Welding in Space

Solidification type welding process experiments in conditions of microgravity were performed. The role of convection in such phenomena was examined and convective effects in the small volumes obtained in the laser weld zone were observed. Heat transfer within the weld was affected by acceleration level as indicated by the resulting microstructure changes in low gravity. All experiments were performed such that both high and low gravity welds occurred along the same weld beam, allowing the effects of gravity alone to be examined. Results indicate that laser welding in a space environment is feasible and can be safely performed IVA or EVA. Development of the hardware to perform the experiment in a Hitchhiker-g platform is recomended as the next step. This experiment provides NASA with a capable technology for welding needs in space. The resources required to perform this experiment aboard a Shuttle Hitchhiker-pallet are assessed. Over the four year period 1991 to 1994, it is recommended that the task will require 13.6 manyears and

Microwave Extraction of Water from Lunar Regolith Simulant

914,900. In addition to demonstrating the technology and ferreting out the problems encountered, it is suggested that NASA will also have a useful laser materials processing facility for working with both the scientific and the engineering aspects of materials processing in space. Several concepts are also included for long-term optimization of available solar power through solar pumping solid state lasers directly for welding power.

Microwave Processing of Planetary Surfaces for the Extraction of Volatiles

Nearly a decade ago the DOD Clementine lunar orbital mission obtained data indicating that the permanently shaded regions at the lunar poles may have permanently frozen water in the lunar soil or ‘permafrost’. Currently a Lunar Lander Exploration Program is expected to land at the lunar pole to determine if water is present. The detection of water from the permafrost is an important goal for NASA. Extraction of water from lunar permafrost would be a valuable In‐Situ Resource for Utilization (ISRU) in human life support and as a fuel. The use of microwave processing could permit the extraction of water without the need to dig, drill, or excavate the lunar surface. Microwave heating of regolith is potentially faster and more efficient than any other heating methods due to the very low thermal conductivity of the lunar regolith. Also, microwaves can penetrate into the soil permitting water removal from deep below the lunar surface. A cryogenic vacuum test facility was developed for evaluating the use of micr...

Fluid Merging Viscosity Measurement (FMVM) Experiment on the International Space Station

In-Situ Resource Utilization will be necessary for sustained exploration of space. Volatiles are present in planetary soils, but water by far has the most potential for effective utilization. The presence of water at the lunar poles, Mars, and possibly on Phobos opens the possibility of producing LOX for propellant. Water is also a useful radiation shielding material , and valuable to replenish expendables (water and oxygen) required for habitation in space. Because of the strong function of water vapor pressure with temperature, heating soil effectively liberates water vapor by sublimation. Microwave energy will penetrate soil and heat from within much more efficiently than heating from the surface with radiant heat. This is especially true under vacuum conditions since the heat transfer rate is very low. The depth of microwave penetration is a strong function of the microwave frequency and to a lesser extent on soil dielectric properties. Methods for complex electric permittivity and magnetic permeability measurement are being developed and used for measurements of lunar soil simulants. A new method for delivery of microwaves deep into a planetary surface is being prototyped with laboratory experiments and modeled with COMSOL MultiPhysics. We are planning to set up a planetary testbed in a large vacuum chamber in the coming year. Recent results are discussed.

Electrical properties of Al-In-Sn alloys directionally solidified in high and low gravitational fields

The concept of using low gravity experimental data together with fluid dynamical numerical simulations for measuring the viscosity of highly viscous liquids was recently validated on the International Space Station (ISS). After testing the proof of concept for this method with parabolic flight experiments, an ISS experiment was proposed and later conducted onboard the ISS in July, 2004 and subsequently in May of 2005. In that experiment a series of two liquid drops were brought manually together until they touched and then were allowed to merge under the action of capillary forces alone. The merging process was recorded visually in order to measure the contact radius speed as the merging proceeded. Several liquids were tested and for each liquid several drop diameters were used. It has been shown that when the coefficient of surface tension for the liquid is known, the contact radius speed can then determine the coefficient of viscosity for that liquid. The viscosity is determined by fitting the experimental speed to theoretically calculated contact radius speed for the same experimental parameters. Experimental and numerical results will be presented in which the viscosity of different highly viscous liquids were determined, to a high degree of accuracy, using this technique.

Finite Element Analysis of Three Methods for Microwave Heating of Planetary Surfaces

Al-ln-Sn alloys have been directionally solidified in the NASA KC-135 aircraft which flies a series of parabolas to generate high (high-g) and low gravity (low-g) forces parallel to the longitudinal growth axis. Thus, for a given sample successive sections can be identified which were solidified in high-g and in low-g. Measurements on the electronic properties of the samples reveal that (1) the resistivity of the low-g sections is larger (about a factor of 10) than that of the high-g sections; (2) the low-g sections behave conductively like a semi-metal, while the high-g sections are essentially metallic; and (3) both high-g and low-g sections are superconducting but the superconducting transition temperature of the low-g sections is 1 K higher than that of the high-g sections.

Extraction of Water from Polar Lunar Permafrost with Microwaves - Dielectric Property Measurements

In-Situ Resource Utilization will be Ground Breaking technology for sustained exploration of space. Volatiles are present in planetary regolith, but water by far has the most potential for effective utilization. The presence of water at the lunar poles and Mars opens the possibility of using the hydrogen for propellant on missions beyond Earth orbit. Likewise, the oxygen could be used for in-space propulsion for lunar ascent/descent and for space tugs from low lunar orbit to low Earth orbit. Water is also an effective radiation shielding material as well as a valuable expendable (water and oxygen) required for habitation in space. Because of the strong function of water vapor pressure with temperature, heating regolith effectively liberates water vapor by sublimation. Microwave energy will penetrate soil and heat from within, much more efficiently than heating from the surface with radiant heat. This is especially true under vacuum conditions since the heat transfer rate is very low. The depth of microwave penetration is a strong function of the microwave frequency and to a lesser extent on regolith dielectric properties. New methods for delivery of microwaves into lunar and planetary surfaces is being prototyped with laboratory experiments and modeled with COMSOL MultiPhysics. Recent results are discussed.

In-situ x-ray microscopy of phase and composition distributions in metal alloys during solidification

Remote sensing indicates the presence of hydrogen rich regions associated with the lunar poles. The logical hypothesis is that there is cryogenically trapped water ice located in craters at the lunar poles. Some of the craters have been in permanent darkness for a billion years. The presence of water at the poles as well as other scientific advantages of a polar base, have influenced NASA plans for the lunar outpost. The lunar outpost has water and oxygen requirements on the order of 1 ton per year scaling up to as much as 10 tons per year. Microwave heating of the frozen permafrost has unique advantages for water extraction. Proof of principle experiments have successfully demonstrated that microwaves will couple to the cryogenic soil in a vacuum and the sublimed water vapor can be successfully captured on a cold trap. The dielectric properties of lunar soil will determine the hardware requirements for extraction processes. Microwave frequency dielectric property measurements of lunar soil simulant have been measured.

Advancement of x-ray microscopy technology and its application to metal solidification studies

This research applies a state of the art x-ray transmission microscope, to image the solidification of metallic or semiconductor alloys in real-time. By employing a hard x-ray source with sub-micron dimensions, resolutions of up to 2 micrometers can be obtained with magnifications of over 800 X. Specimen growth conditions were optimized and the best imaging technologies applied to maintain x-ray image resolution, contrast and sensitivity. In addition, a special furnace design is required to permit controlled growth conditions and still offer maximum resolution and image contrast. We have successfully imaged in real-time: interfacial morphologies, phase growth, coalescence, incorporation of phases into the growing interface, and the solute boundary layer in the liquid at the solid-liquid interface. We have also measured true local growth rates and can evaluate segregation structures in the solid; a form of in situ metallography. Composition gradients within the specimen cause variations in absorption of the flux such that the final image represents a spatial integration of composition. During this study, the growth of secondary phase fibers and lamellae form eutectic and monotectic alloys have been imaged during solidification, in real-time, for the first time in bulk metal alloys.