Search

Mathematical models, both 2-D and 3-D, are developed to represent g-jitter induced fluid flows and their effects on solidification under combined action of magnetic fields and microgravity. The numerical model development is based on the finite element solution of governing equations describing the transient g-jitter driven fluid flows, heat transfer and solutal transport during crystal growth with and without an applied magnetic field in space vehicles. To validate the model predictions, a ground-based g-jitter simulator is developed using the oscillating wall temperatures where timely oscillating fluid flows are measured using a laser PIV system. The measurements are compared well with numerical results obtained from the numerical models. Results show that a combined action derived from magnetic damping and microgravity can be an effective means to control the melt flow and solutal transport in space single crystal growth systems.

A 2-D finite element model is presented for the melt growth of single crystals in a microgravity environment with a superimposed DC magnetic field. The model is developed based on the deforming finite element methodology and is capable of predicting the phenomena of the steady and transient convective flows, heat transfer, solute distribution, and solid-liquid interface morphology associated with the melt growth of single crystals in microgravity with and without an applied magnetic field. Numerical simulations were carried out for a wide range of parameters including idealized microgravity conditions, the synthesized g-jitter and the real g-jitter data taken by on-board accelerometers during space flights. The results reveal that the time varying g-jitter disturbances, although small in magnitude, cause an appreciable convective flow in the liquid pool, which in turn produces detrimental effects during the space processing of single crystal growth. An applied magnetic field of appropriate strength, superimposed on microgravity, can be very effective in suppressing the deleterious effects resulting from the g-jitter disturbances.

This paper describes a numerical study of the g-jitter driven double diffusive convective flows, thermal and concentration distributions in binary alloy melt systems subject to an external magnetic field. The study is based on the finite element solution of transient magnetohydrodynamic equations governing the momentum, thermal and solutal transport in the melt pool. Numerical simulations are conducted using the synthesized single- and multi- frequency g-jitter as well as the real g-jitter data taken during space flights with or without an applied magnetic field. It is found that for the conditions studied, the main melt flow follows approximately a lineal- superposition of velocity components induced by individual g-jitter components, regardless of whether a magnetic field exists or not. The flow field is characterized by a recirculating double diffusive convection loop oscillating in time with a defined frequency equal to that of the driving g-jitter force. An applied magnetic field has little effect on the oscillating recirculating pattern, except around the moment in time when the flow reverses its direction. The field has no effect on the oscillation period, but it changes the phase angle. It is very effective in suppressing the flow intensity and produces a notable reduction of the solutal striation and time fluctuations in the melt. For a given magnetic field strength, the magnetic damping effect is more pronounced on the velocity associated with the largest g-jitter component present and/or the g-jitter spiking peaks. A stronger magnetic field is more effective in suppressing the melt convection and also is more helpful in bringing the convection in phase with the g-jitter driving force. The applied field is particularly useful in suppressing the effect of real g-jitter spikes on both flow and solutal distributions. With appropriately selected magnetic fields, the convective flows caused by g-jitter can be reduced sufficiently and diffusion dominant. solutal transport in the melt is possible.

A finite element study is presented of double-diffusive convection driven by g-jitter in a microgravity environment. Mathematical formulations are presented and extensive simulations are carried out for g-jitter induced fluid flow, temperature distribution, and solutal transport in an alloy system under consideration for space flights. Computations include the use of idealized single-frequency and multi-frequency g-jitter as well as the real g-jitter data taken during an actual Space Shuttle fight. Little correlation is seen between these velocity components for the g-jitter components studied. The temperature field is basically undisturbed by convection because of a small Pr number for the fluid. The disturbance of the concentration field, however, is pronounced, and the local variation of the concentration follows the velocity oscillation in time. It is found that although the concentration field varies in both position and time, the local concentration gradient remains approximately constant in time. Numerical study further indicates that with an increase in g-jitter force (or amplitude), the nonlinear convective effects become much more obvious, which in turn drastically change the concentration fields. The simulated results computed using the g-jitter data taken during space flights show that both the velocity and concentration become random, following approximately the same pattern as the g-jitter perturbations.

A fully 3-D, transient finite element model is developed to represent the magnetic damping effects on complex fluid flow, heat transfer and electromagnetic field distributions in a Sn- 35.5%Pb melt undergoing unidirectional solidification. The model is developed based on our in- house finite element code for the fluid flow, heat transfer and electromagnetic field calculations. The numerical model is tested against numerical and experimental results for water as reported in literature. Various numerical simulations are carried out for the melt convection and temperature distribution with and without the presence of a transverse magnetic field. Numerical results show that magnetic damping can be effectively applied to stabilize melt flow, reduce turbulence and flow levels in the melt and over a certain threshold value a higher magnetic field resulted in a greater reduction in velocity. Also, for the study of melt flow instability, a long enough running time is needed to ensure the final fluid flow recirculation pattern. Moreover, numerical results suggest that there seems to exist a threshold value of applied magnetic field, above which magnetic damping becomes possible and below which the 0 convection in the melt is actually enhanced.

A 3-D numerical model is developed to represent the oscillating natural convection induced in a cylindrical cavity filled with Ga-doped germanium with and without the presence of an external magnetic field. The model is developed based on the penalty-finite element solution of the equations describing the transport of momentum, heat and solutal element as well as the electromagnetic field distribution in the melt pool. Automatic time step control is applied to help speed up the calculations. Numerical simulations are conducted to study the convection and magnetic damping effects as a function of frequency, directions and amplitudes of g-jitter and also the direction and magnitudes of the applied magnetic fields. The results show that the g-jitter driven flow is time dependent and exhibits a complex recirculating convection pattern in three dimensions and that an applied magnetic field can be employed to suppress this deleterious convective flow and both magnitude and orientation of the applied field are important in magnetic damping of the g-jitter induced convective flows.

Significant progress has been made toward all of the goals for the first phase of the project short of actual fabrication of a light path. Two alternative approaches to fabricating gold mirrors using the basic LIGA process were developed, one using electroplated solid gold mirrors and the second using gold plated over a nickel base. A new method of fabrication, the transfer mask process, was developed and demonstrated. Analysis of the projected surface roughness and beam divergence effects was completed. With gold surface with low surface roughness scattering losses are expected to be insignificant. Beam divergence due to diffraction will require a modification of the original design, but should be eliminated by fabricating mirrors 1000 mu m in height by 1000 mu m in width and using a source with an initial beam radius greater than 300 mu m. This may eliminate any need for focusing optics. Since the modified design does not affect the mask layout, ordering of the mask and fabrication of the test structures can begin immediately at the start of Phase 1.