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. Measurements of thermophysical properties on ground are often difficult, or even impossible, since liquids are strongly influenced by earth's gravity. Another problem is the reactivity of melts with container materials, especially at high temperature. Finally, deep undercooling, necessary to understand nucleus formation and equilibrium as well as non-equilibrium solidification, can only be achieved in a containerless environment. Containerless experiments in microgravity allow precise benchmark measurements of thermophysical properties. The electromagnetic levitator ISS-EML on the International Space Station (ISS) offers perfect conditions for such experiments. This way, data for process simulations is obtained, and a deeper understanding of nucleation, crystal growth, microstructural evolution, and other details of the transformation from liquid to solid can be gained. Here, we address the scientific questions in detail, show highlights of recent achievements, and give an outlook on future work.

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. Models of the magnetohydrodynamic flow indicated that turbulence was present during the measurement in the ISS-EML facility, which accounts for the observed difference.

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 Zr57Cu15.4Ni12.6Al10Nb5 (Vit106), as well as Cu50Zr50 and the quasicrystal-forming Ti39.5Zr39.5Ni21 liquids. The maximum supercooling temperatures for each alloy were measured as a function of controlled stirring by applying various combinations of radio-frequency positioner and heater voltages to the water-cooled copper coils. The flow patterns were simulated from the known parameters for the coil and the levitated samples. The maximum nucleation temperatures increased systematically with increased fluid flow in the liquids for Vit106, but stayed nearly unchanged for the other two. These results are consistent with the predictions from the Coupled-Flux model for nucleation.

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. However, property measurements must use noncontact methods as well. Fortunately, several optical-based methods have been developed and successfully employed to measure thermophysical properties, including surface tension, viscosity, density, and thermal expansion. Combining these techniques with the electrostatic levitator (ESL) located at the NASA Marshall Space Flight Center (MSFC) has resulted in an excellent facility to perform containerless material studies which support microgravity flight projects. Currently, studies of the thermophysical properties of liquid quasi-crystal forming and related alloys ranging from superheated to deeply undercooled states are being done with this facility in support of the NASA-funded flight project Quasi-crystalline Undercooled Alloys for Space Investigation (QUASI). While the primary purpose of these measurements is to support planned flight experiments, they are also a desirable resource for future manufacturing considerations and for fundamental insight in the physics of icosahedral ordering in liquids and solids. Presented here is an overview of the contactless measuring methods for surface tension, viscosity, density, and thermal expansion applied to Zr54Ti8Cu20Al10Ni8, for the superheated and meta-stable undercooled liquid phases, in support of QUASI.

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.

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. This is the first experimental observation of distorted icosahedral short-range order in any liquid, although this has been predicted by theoretical studies on atomic clusters.

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 Ti39.5Zr39.5Ni21 liquid. A new experimental facility, BESL (Beamline Electrostatic Levitation), was developed to enable the synchrotron x-ray structural studies on deeply undercooled, reactive liquids.