ALBERT

Description: Combustion synthesis, otherwise known as self-propagating high temperature synthesis (SHS), can be used to produce engineered advanced porous material implants which offer the possibility for bone ingrowth as well as a permanent structure framework for the long-term replacement of bone defects. The primary advantage of SHS is based on its rapid kinetics and favorable energetics. The structure and properties of materials produced by SHS are strongly dependent on the combustion reaction conditions. Combustion reaction conditions such as reaction stoichiometry, particle size, green density, the presence and use of diluents or inert reactants, and pre-heating of the reactants, will affect the exothermicity of the reaction. A number of conditions must be satisfied in order to obtain high porosity materials: an optimal amount of liquid, gas and solid phases must be present in the combustion front. Therefore, a balance among these phases at the combustion front must be created by the SHS reaction to successfully engineer a bone replacement material system. Microgravity testing has extended the ability to form porous products. The convective heat transfer mechanisms which operate in normal gravity, 1 g, constrain the combustion synthesis reactions. Gravity also acts to limit the porosity which may be formed as the force of gravity serves to restrict the gas expansion and the liquid movement during reaction. Infiltration of the porous product with other phases can modify both the extent of porosity and the mechanical properties.

Description: Combustion synthesis (self propagating, high temperature synthesis-SHS) is a novel technique that is capable of producing many advanced materials. The ignition temperature (Tig) of such combustion synthesis reactions is often coincident with that of the lowest melting point reactant. The resultant liquid metal wets and spreads around the other solid reactant particles of higher melting points, thereby improving the reactant contact and kinetics, followed by formation of the required compounds. This ignition initiates a combustion propagating wave whose narrow reaction front rapidly travels through the reactants. Since this process is highly exothermic, the heat released by combustion often melts the reactant particles ahead of the combustion front and ignites the adjacent reactant layer, resulting in a self-sustaining reaction. Whenever a fluid phase (liquid or gas) is generated by the reaction system, gravity-driven phenomena can occur. Such phenomena include convective flows of fluid by conventional or unstable convection and settling of the higher density phases. A combustion process is often associated with various kinds of fluid flow. For instance, if the SHS reaction is carried out under inert or reactive gas atmospheres, or a volatile, e.g., B2O3, is deliberately introduced as a reactant, convective flows of the gas will occur due to a temperature gradient existing in the atmosphere when a combustion wave is initiated. The increased gas flow will produce a porous (or expanded) SHS product. Owing to the highly exothermic nature of many SHS reactions, liquid phase(s) can also form before, at, or after the combustion front. The huge temperature gradient at the combustion front can induce convective flows (conventional or unstable) of the liquid phase. Each of these types of convective fluid flow can change the combustion behavior of the synthesizing reaction, and, therefore, the resultant product microstructure. In addition, when two or more phases of different density are produced at or ahead of the propagating combustion front settling of the higher density phase will occur resulting in a non-uniform product microstructure and properties.

Description: Glass ceramic composites based on B2O3-Al2O3-MgO have been produced by combustion synthesis in a Self-propagating mode. The gravitational effects on the combustion characteristics such as combustion wave velocity (V), and combustion temperature (T(sub c)) were studied. The results showed that the gravitational effects on these parameters were inconclusive. The microstructure of this system has also been analyzed with X-ray Diffraction and light microscopy. These results showed a higher amount of divitrification occurs under both reduced gravity and high gravity conditions. The gravitational effects on formation of pores, overall porosity and apparent porosity for this family of glass-ceramics also shows to be inconclusive. Possible reasons for these results are discussed.

Description: The Combustion Synthesis technique has been used to produce glasses based on B2O3-Al2O3-MgO and CaO-Al2O3. The combustion characteristics of these combustion synthesis reactions using both small cylindrical pellets (SCP) and large spherical pellets (LSP) are presented. Low density pellets (approx. 35% of their theoretical density) were used, which made synthesis of low exothermic combustion reactions possible. Microstructural analysis of reacted samples was carried out to identify the glass-forming compositions. The effects of gravity on the glass formation were studied aboard the KC-135 using SCP samples. Gravity seemed to have such obvious effects on the combustion characteristics that the wave velocity was lower and the Width of the combustion wave was larger under reduced gravity conditions. Samples produced under low gravity also had more enhanced vitrification than those on ground, while some systems also exhibited lower combustion temperatures. It was also found that the container significantly affects both the combustion characteristics and microstructure. Substantially more divitrification occurred at the area which was in contact with the support (container).

Description: Production of highly porous composite materials by traditional materials processing is limited by difficult processing techniques. This work investigates the use of self propagating high temperature (combustion) synthesis (SHS) to create porous tricalcium phosphate (Ca3(PO4)2), TiB-Ti, and NiTi in low and microgravity. Combustion synthesis provides the ability to use set processing parameters to engineer the required porous structure suitable for bone repair or replacement. The processing parameters include green density, particle size, gasifying agents, composition, and gravity. The advantage of the TiB-Ti system is the high level of porosity achieved together with a modulus that can be controlled by both composition (TiB-Ti) and porosity. At the same time, NiTi exhibits shape memory properties. SHS of biomaterials allows the engineering of required porosity coupled with resorbtion properties and specific mechanical properties into the composite materials to allow for a better biomaterial.