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The growth of the alloy compound semiconductor lead tin telluride (PbSnTe) was chosen for a microgravity flight experiment in the Advanced Automated Directional Solidification Furnace (AADSF), on the United States Microgravity Payload-3 (USNP-3) in February, 1996 and on USNW- 4 in November, 1997. The objective of these experiments was to determine the effect of the reduction in convection, during the growth process, brought about by the microgravity environment. The properties of devices made from PbSnTe, an alloy of PbTe and SnTe, are dependent on the ratio of the elemental components in the starting crystal. Compositional uniformity in the crystal is only obtained if there is no significant mixing in the liquid during growth. The technological importance of PbSnTe lies in its band gap versus composition diagram which has a zero energy crossing at approximately 40% SnTe. This facilitates the construction of long wavelength (greater than 6 gm) infrared detectors and lasers. The properties and utilization of PbSnTe are the subject of other papers. 1,2 PbSnTe is also interesting from a purely scientific point of view. It is, potentially, both solutally and thermally unstable due to the temperature and density gradients present during growth. Density gradients, through thermal expansion, are imposed in directional solidification because temperature gradients are required to extract heat. Solutal gradients occur in directional solidification of alloys due to segregation at the interface. Usually the gradients vary with both experiment design and inherent materials properties. In a simplified one dimensional analysis with the growth axis parallel to the gravity vector, only one of the two instabilities work at a time. During growth, the temperature in the liquid increases ahead of the interface. Therefore the density, due to thermal expansion, is decreasing in that direction. However, the phase diagram shows that the lighter SnTe is preferentially rejected at the interface. This causes the liquid density to increase with distance away from the interface.

The growth of the alloy compound semiconductor lead tin telluride (PbSnTe) was chosen for a microgravity flight experiment in the Advanced Automated Directional Solidification Furnace (AADSF), on the United States Microgravity Payload-3 (USMP-3) and on USMP-4 Space Shuttle flights in February, 1996, and November, 1997. The objective of these experiments was to determine the effect of the reduction in convection, during the growth process, brought about by the microgravity environment. The properties of devices made from PbSnTe are dependent on the ratio of the elemental components in the starting crystal. Compositional uniformity in the crystal is only obtained if there is no significant mixing in the liquid during growth. Lead tin telluride is an alloy of PbTe and SnTe. The technological importance of PbSnTe lies in its band gap versus composition diagram which has a zero energy crossing at approximately 40% SnTe. This facilitates the construction of long wavelength (>6 micron) infrared detectors and lasers. Observations and experimental methods of crystal growth of PbSnTe on both Space Shuttle Flights are presented.

The wall drag test tunnel at NASA Langley Research Center was used to evaluate simulated scramjet fuel injection into a wall cavity. In this tunnel, one wall consists of interchangeable aluminum plates attached to an air bearing suspension system. The plates were equipped with load cells to measure drag forces and static taps to determine pressure distributions. The plates were exposed to a Mach 2 air stream at a total pressure of 115 psia (793 kPa). This flow field contained a train of weak unsteady, reflecting shock waves that were produced in the nozzle assembly located upstream of the test section.

An experimental program was conducted at NASA Langley Research Center that included development and evaluation of an operational facility for wall drag measurement of potential scramjet fuel injection or wall cooling configurations. The facility consisted of a supersonic tunnel, with one wall composed of a series of interchangeable aluminum plates attached to an air bearing suspension system. The system was equipped with load cells that measured drag forces of 115 psia (793 kPa). This flow field contained a train of weak, unsteady, reflecting shock waves that were produced in the Mach 2 nozzle flows, the effect of reflecting shocks (which are to be expected in scramjet combustors) in internal flows has not previously been documented.

Experiments on relaminarization, or reverse transition of turbulent flow, have been conducted with a scramjet combustor and nozzle model. The Mach-2.7 direct-connect scramjet combustor employed swept-ramp fuel injectors, and the entering flow simulated Mach-6 to Mach-7 flight conditions. Tests were also conducted without combustor fuel to produce a higher nozzle entrance Mach number and lower pressures. Additional tests were conducted to evaluate the effectiveness of film cooling on the cowl region. At each test condition studied, the entrance radius had no significant effect on the measured downstream wall heating rates. Analysis of the data when fuel was injected into the combustor shows good agreement with turbulent theory; for the tests without fuel injection and combustion, the data downstream of the nozzle entrance radius are intermediate to the calculated turbulent and laminar solutions. Results of film-cooling tests, conducted with both hydrogen and nitrogen injectants, showed that, per unit mass, the hydrogen was approximately three to four times more effective than nitrogen in reducing the downstream wall heating rates.

A scramjet combustor with four wall-ramp injectors containing Mach-1.7 fuel jets in the base of the ramps was investigated experimentally. During the test program, two swept ramp injector designs were evaluated. One swept-ramp model had 10-deg compression-ramps and the other had 10-deg expansion cavities between flush wall ramps. The scramjet combustor model was instrumented with pressure taps and heat-flux gages. The pressure measurements indicated that both injector configurations were effective in promoting mixing and combustion. Autoignition occurred for the compression-ramp injectors, and the fuel began to burn immediately downstream of the injectors. In tests of the expansion ramps, a pilot was required to ignite the fuel, and the fuel did not burn for a distance of at least two gaps downstream of the injectors. Once initiated, combustion was rapid in this configuration. Heat transfer measurements showed that the heat flux differed greatly both across the width of the combustor and along the length of the combustor.

An experimental study has been performed with a scramjet combustor and nozzle model to determine the effect of nozzle radii on relaminarization, and the effectiveness of film injection in reducing wall heat flux. The nozzle model was installed downstream of a swept-ramp scramjet combustor model, operated at Mach 2.7 with vitiated air, simulating Mach 6-7 flight enthalpies. Results from tests conducted with three nozzle radii, varying in curvature from a sharp Prandtl-Meyer expansion to a radius of two scramjet combustor exit heights, showed little or no effect on the downstream wall heat flux, which is not in agreement with both subsonic and supersonic relaminarization correlations in the available literature. In contrast, film injection upstream of all three radii produced reductions of 70 percent in the entire nozzle model heating rate, for the nominal film-to-free stream pressure matched condition. Results from film injection, with and without pressure gradient, but without wall curvature, show that the gradients appear to stabilize the film, with the resulting reductions in wall heat transfer rates apparent far downstream of the point of injection.

A methodology for the analysis of a film cooled combustor of a hydrogen-fueled, supersonic combustion ramjet (scramjet) is presented. The SHIP3D parabolic flow code, based on an extension of the pressure-correction method of Patankar and Spalding for compressible flow is used to compute the flow field in the combustor. The effect of film cooling on the overall vehicle performance is then calculated using the one-dimensional, multistep cycle code, CPIPE. Results are presented for a conceptual combustor at Mach 16 flight conditions. It is seen that film cooling can have a significant effect on the engine performance.

An experimental program was conducted to establish some design parameters important to a supersonic film cooling system in a scramjet engine. A simple non-combusting two-dimensional flow configuration was used to isolate the film cooling phenomena. Parameters investigated include coolant delivery pressure, slot height and lip thickness, and incident shock location and strength. Design guidelines for use in engineering and trade studies are presented.