Mold Filling in Micro-gravity and Strength Analysis of the Cast Material
Material Science
A proposal from the “MFM SACM” team at the
University of Wisconsin – Madison
Consideration Requested for
NASA’s 2002 RGSFO Program
| Team Contact: | Molly Mitten |
| Other team members: | Anders Brown |
| Luke Henke | |
| Chaine Selig |
| Faculty advisors: | Professor Sindo Kou |
| Professor Daniel Kammer |
ACADEMIC INSTITUTION:
University of Wisconsin - Madison Peterson Building 750 University Ave. Madison, WI 53706
Synopsis:
The proposed experiment is intended to investigate the process and results of metal casting in micro-gravity. On earth, the common process of casting depends heavily on gravity. A molten metal is injected into a mold from the bottom and fills to the top. Gravity keeps the metal on the bottom of the mold and air rises to the top and escapes from vents in the mold. This process greatly reduces air pockets within the metal that cause voids in the cast piece. Voids can reduce the strength of a material, or make its properties non-uniform. With the construction of the International Space Station, and an increased human presence in space, it would be beneficial to manufacture some pieces of hardware in space. In a reduced gravity environment, the filling of the mold is more complicated as there is no simple way to separate the metal from the air. By comparing the flow of metal into a mold in a micro-gravity environment to the flow within earth's gravity, the formation of voids can be studied and methods can be developed to reduce the occurrence of these voids. The samples cast in a reduced-gravity environment are likely to be structurally different as well. Examination of the microstructure and testing of the material properties will give evidence of the role gravity plays in the casting of common metals.
The process proposed involves injecting a molten metal (a low melting point solder) into a clear mold and letting the metal cool, all within a 20 second period in micro gravity. Video equipment will record the filling of the mold so the formation of voids can be studied. On the ground, the cast metal will be examined and tested to determine material properties. Results will be compared to similar metal castings performed under earth's gravity.
Related Links:
Johnson Space Center's Student Flight Opportunities Program
UW-Madison Engineering Mechanics and Astronautics
UW-Madison Mechanical Engineering