Electromagnetic levitation containerless processing of metallic materials in microgravity: thermophysical properties.

Transitions from the liquid to the solid state of matter are omnipresent. They form a crucial step in the industrial solidification of metallic alloy melts and are greatly influenced by the thermophysical properties of the melt. Knowledge of the thermophysical properties of liquid metallic alloys is necessary in order to gain a tight control over the solidification pathway, and over the obtained material structure of the solid.

Examining the influence of turbulence on viscosity measurements of molten germanium under reduced gravity.

The thermophysical properties of liquid germanium were recently measured both in parabolic flight experiments and on the ISS in the ISS-EML facility. The viscosity measurements differed between the reduced gravity experiments and the literature values. Since the oscillating drop method has been widely used in EML, further exploration into this phenomenon was of interest.

Impact of convection on the damping of an oscillating droplet during viscosity measurement using the ISS-EML facility.

Oscillating droplet experiments are conducted using the Electromagnetic Levitation (EML) facility under microgravity conditions. The droplet of molten metal is internally stirred concurrently with the pulse excitation initiating shape oscillations, allowing viscosity measurement of the liquid melts based on the damping rate of the oscillating droplet. We experimentally investigate the impact of convection on the droplet's damping behavior.

Demonstration of the effect of stirring on nucleation from experiments on the International Space Station using the ISS-EML facility.

The effect of fluid flow on crystal nucleation in supercooled liquids is not well understood. The variable density and temperature gradients in the liquid make it difficult to study this under terrestrial gravity conditions. Nucleation experiments were therefore made in a microgravity environment using the Electromagnetic Levitation Facility on the International Space Station on a bulk glass-forming ZrCuNiAlNb (Vit106), as well as CuZr and the quasicrystal-forming TiZrNi liquids.

Numerical representations for flow velocity and shear rate inside electromagnetically levitated droplets in microgravity.

Electromagnetic levitation techniques are used in a microgravity environment to allow materials research under containerless conditions while limiting the influence of gravity. The induced advective flow inside a levitated molten alloy droplet is a key factor affecting solidification phenomena while potentially influencing the measurement of thermophysical properties of metallic alloy. It is thus important to predict the flow velocity under various operation conditions during melt processing.

A hybrid approach to simulating mechanical properties of polymer nanocomposites.

Empirical studies indicate that a polymer reinforced with nanoscale particles could enhance its mechanical properties such as stiffness and toughness. To give insight into how and why this nanoparticle reinforcement is effective, it is necessary to develop computational models that can accurately simulate the effects of nanoparticles on the fracture characteristics of polymer composites. Furthermore, a hybrid model that can account for both continuum and non-continuum effects will hasten the development of not only new hierarchical composite materials but also new theories to explain their behavior.

Containerless measurements of thermophysical properties of Zr54Ti8Cu20Al10Ni8.

High-temperature measurement and study of reactive materials can be difficult with conventional processing methods because contamination from the measuring apparatus and container walls can adversely affect measurements. Containerless processing techniques can be employed to isolate samples from their environment, reducing contamination. Benefits of containerless processing include reduction in heterogeneous nucleation sites, which in turn delays the onset of solidification and allows the study of meta-stable undercooled phases.

Microgravity experiments on the effect of internal flow on solidification of Fe-Cr-Ni stainless steels.

A new hypothesis has been developed to explain the effect of internal fluid flow on the lifetime of a metastable phase in solidifying Fe-Cr-Ni alloys. The hypothesis shows excellent agreement with available experimental results, but microgravity experiments are required for complete validation. Certain Fe-Cr-Ni stainless steel alloys solidify from an undercooled melt by a two-step process in which the metastable ferrite phase forms first followed by the stable austenite phase.

In situ high-energy x-ray diffraction study of the local structure of supercooled liquid Si.

Employing the technique of electrostatic levitation, coupled with high-energy x-ray diffraction and rapid data acquisition methods, we have obtained high quality structural data more deeply into the supercooled regime of liquid silicon than has been possible before. No change in coordination number is observed in this temperature region, calling into question previous experimental claims of structural evidence for the existence of a liquid-liquid phase transition.

Convection in containerless processing.

Different containerless processing techniques have different strengths and weaknesses. Applying more than one technique allows various parts of a problem to be solved separately. For two research projects, one on phase selection in steels and the other on nucleation and growth of quasicrystals, a combination of experiments using electrostatic levitation (ESL) and electromagnetic levitation (EML) is appropriate.

Contrasting electrostatic and electromagnetic levitation experimental results for transformation kinetics of steel alloys.

The delay between conversion of metastable ferrite to stable austenite during ternary Fe-Cr-Ni alloy double recalescence is seen to differ by over an order of magnitude for tests conducted using electrostatic and electromagnetic levitation. Several possible reasons for this deviation are proposed. Thermodynamic calculations on evaporation rates indicate that potential composition shifts during testing are minimized by limiting test time and thermal history.

Difference in icosahedral short-range order in early and late transition metal liquids.

New short-range order data are presented for equilibrium and undercooled liquids of Ti and Ni. These were obtained from in situ synchrotron x-ray diffraction measurements of electrostatically levitated droplets. While the short-range order of liquid Ni is icosahedral, consistent with Frank's hypothesis, significantly distorted icosahedral order is observed in liquid Ti.

First x-ray scattering studies on electrostatically levitated metallic liquids: demonstrated influence of local icosahedral order on the nucleation barrier.

To explain the unusual stability of undercooled liquids against crystallization, Frank hypothesized that the local structures of undercooled liquids contain a significant degree of icosahedral short-range order, which is incompatible with long-range periodicity. We present here the first direct experimental demonstration of Frank's complete hypothesis, showing a correlation between the nucleation barrier and a growing icosahedral short-range order with decreasing temperature in a Ti39.5Zr39.