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All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Electrostatic Levitation for Studies of Additive Manufactured Materials

The electrostatic levitation (ESL) laboratory at NASA's Marshall Space Flight Center is a unique facility for investigators studying high temperature materials. The laboratory boasts two levitators in which samples can be levitated, heated, melted, undercooled, and resolidified. Electrostatic levitation minimizes gravitational effects and allows materials to be studied without contact with a container or instrumentation. The lab also has a high temperature emissivity measurement system, which provides normal spectral and normal total emissivity measurements at use temperature. The ESL lab has been instrumental in many pioneering materials investigations of thermophysical properties, e.g., creep measurements, solidification, triggered nucleation, and emissivity at high temperatures. Research in the ESL lab has already led to the development of advanced high temperature materials for aerospace applications, coatings for rocket nozzles, improved medical and industrial optics, metallic glasses, ablatives for reentry vehicles, and materials with memory. Modeling of additive manufacturing materials processing is necessary for the study of their resulting materials properties. In addition, the modeling of the selective laser melting processes and its materials property predictions are also underway. Unfortunately, there is very little data for the properties of these materials, especially of the materials in the liquid state. Some method to measure thermophysical properties of additive manufacturing materials is necessary. The ESL lab is ideal for these studies. The lab can provide surface tension and viscosity of molten materials, density measurements, emissivity measurements, and even creep strength measurements. The ESL lab can also determine melting temperature, surface temperatures, and phase transition temperatures of additive manufactured materials. This presentation will provide background on the ESL lab and its capabilities, provide an approach to using the ESL in supporting the development and modeling of the selective laser melting process for metals, and provide an overview of the results to date.

SanSoucie, Michael P.↗
NASA NTRS2015

The NASA MSFC Electrostatic Levitation (ESL) Laboratory: Summary of Capabilities, Recent Upgrades, and Future Work

The NASA Marshall Space Flight Center (MSFC) electrostatic levitation (ESL) laboratory has a long history of providing materials research and thermophysical property data. A summary of the labs capabilities, recent upgrades, and ongoing and future work will be provided. The laboratory has recently added two new capabilities to its main levitation chamber: a rapid quench system and an oxygen control system. The rapid quench system allows samples to be dropped into a quench vessel that can be filled with a low melting point material, such as a gallium or indium alloy. Thereby allowing rapid quenching of undercooled liquid metals. The oxygen control system consists of an oxygen sensor, oxygen pump, and a control unit. The sensor is a potentiometric device that determines the difference in oxygen activity between two gas compartments separated by an electrolyte, which is yttria-stabilized zirconia. The pump utilizes coulometric titration to either add or remove oxygen. The system is controlled by a desktop control unit, which can also be accessed via a computer. This system allows the oxygen partial pressure within the vacuum chamber to be measured and controlled, theoretically in the range from 10-36 to 100 bar. The ESL laboratory also has an emissometer, called the High-Temperature Emissivity Measurement System (HiTEMS). This system measures the spectral emissivity of materials from 600degC to 3,000degC. The system consists of a vacuum chamber, a black body source, and a Fourier Transform Infrared Spectrometer (FTIR). The system utilizes optics to swap the signal between the sample and the black body. The system was originally designed to measure the hemispherical spectral emissivity of levitated samples, which are typically 2.5mm spheres. Levitation allows emissivity measurements of molten samples, but more work is required to develop this capability. The system is currently setup measure the near-normal spectral emissivity of stationary samples, which has been used to take measurements of ablative materials, rocket nozzle coating materials, and materials for spacecraft instruments.

SanSoucie, Michael P.↗
NASA NTRS2016

Reduced-Gravity Measurements of the Effect of Oxygen on Properties of Zirconium

The influence of oxygen on the thermophysical properties of zirconium is being investigated using MSL-EML (Material Science Laboratory - Electromagnetic Levitator) on ISS (International Space Station) in collaboration with NASA, ESA (European Space Agency), and DLR (German Aerospace Center). Zirconium samples with different oxygen concentrations will be put into multiple melt cycles, during which the density, viscosity, surface tension, heat capacity, and electric conductivity will be measured at various undercooled temperatures. The facility check-up of MSL-EML and the first set of melting experiments have been successfully performed in 2015. The first zirconium sample will be tested near the end of 2015. As part of ground support activities, the thermophysical properties of zirconium and ZrO were measured using a ground-based electrostatic levitator located at the NASA Marshall Space Flight Center. The influence of oxygen on the measured surface tension was evaluated. The results of this research will serve as reference data for those measured in ISS.

Zhao, J.↗
NASA NTRS2016

Growth Mechanism of Nanowires: Binary and Ternary Chalcogenides

Semiconductor nanowires exhibit very exciting optical and electrical properties including high transparency and a several order of magnitude better photocurrent than thin film and bulk materials. We present here the mechanism of nanowire growth from the melt-liquid-vapor medium. We describe preliminary results of binary and ternary selenide materials in light of recent theories. Experiments were performed with lead selenide and thallium arsenic selenide systems which are multifunctional material and have been used for detectors, acousto-optical, nonlinear and radiation detection applications. We observed that small units of nanocubes and elongated nanoparticles arrange and rearrange at moderate melt undercooling to form the building block of a nanowire. Since we avoided the catalyst, we observed self-nucleation and uncontrolled growth of wires from different places. Growth of lead selenide nanowires was performed by physical vapor transport method and thallium arsenic selenide nanowire by vapor-liquid-solid (VLS) method. In some cases very long wires (>mm) are formed. To achieve this goal experiments were performed to create situation where nanowires grew on the surface of solid thallium arsenic selenide itself.

Singh, N. B.↗
NASA NTRS2016

Growth Mechanism of Nanowires: Ternary Chalcogenides

In the past two decades there has been a large rise in the investment and expectations for nanotechnology use. Almost every area of research has projected improvements in sensors, or even a promise for the emergence of some novel device technologies. For these applications major focuses of research are in the areas of nanoparticles and graphene. Although there are some near term applications with nanowires in photodetectors and other low light detectors, there are few papers on the growth mechanism and fabrication of nanowire-based devices. Semiconductor nanowires exhibit very favorable and promising optical properties, including high transparency and a several order of magnitude better photocurrent than thin film and bulk materials. We present here an overview of the mechanism of nanowire growth from the melt, and some preliminary results for the thallium arsenic selenide material system. Thallium arsenic selenide (TAS) is a multifunctional material combining excellent acousto-optical, nonlinear and radiation detection properties. We observed that small units of (TAS) nanocubes arrange and rearrange at moderate melt undercooling to form the building block of a nanowire. In some cases very long wires (less than mm) are formed. Since we avoided the catalyst, we observed self-nucleation and uncontrolled growth of wires from different places.

Singh, N. B.↗
NASA NTRS2016

Levitation Technology in International Space Station Research

The International Space Station (ISS) is a unique multidisciplinary orbiting laboratory for science and technology research, enabling discoveries that benefit life on Earth and exploration of the universe. ISS facilities for containerless sample processing in Materials Science experiments include levitation devices with specimen positioning control while reducing containment vessel contamination. For example, ESA's EML (ElectroMagnetic Levitator), is used for melting and solidification of conductive metals, alloys, or semiconductors in ultra-high vacuum, or in high-purity gaseous atmospheres. Sample heating and positioning are accomplished through electromagnetic fields generated by a coil system. EML applications cover investigation of solidification and microstructural formation, evaluation of thermophysical properties of highly reactive metals (whose properties can be very sensitive to contamination), and examination of undercooled liquid metals to understand metastable phase convection and influence convection on structural changes. MSL utilization includes development of novel light-weight, high-performance materials. Another facility, JAXA's ELF (Electrostatic Levitation Furnace), is used to perform high temperature melting while avoiding chemical reactions with crucibles by levitating a sample through Coulomb force. ELF is capable of measuring density, surface tension, and viscosity of samples at high temperatures. One of the initial ELF investigations, Interfacial Energy-1, is aimed at clarification of interfacial phenomena between molten steels and oxide melts with industrial applications in control processes for liquid mixing. In addition to these Materials Science facilities, other ISS investigations that involve levitation employ it for biological research. For example, NASA's "Magnetic 3D Culturing and Bioprinting" investigation uses magnetic levitation for three-dimensional culturing and positioning of magnetized cells to generate spheroid assemblies for biomedical applications. Levitation is also used as a modeled microgravity ground analog in the NASA OsteoOmics ISS investigation, which tests whether magnetic levitation accurately simulates microgravity conditions by studying gravitational regulation of osteoblast and osteoclast genomics and metabolism. Elucidating the cellular mechanisms of bone loss in microgravity contributes to the understanding of bone loss in medical disorders on Earth, which may lead to development of preventive or therapeutic countermeasures. Thus, the ISS state-of-the-art laboratory offers various levitation capability platforms with applications for innovative research in Materials and Life Sciences disciplines, with benefits for humanity.

Guinart-Ramirez, Y.↗
NASA NTRS2018

Thermophysical Properties of Nickel-Based Superalloys

The NASA Marshall Space Flight Center (MSFC) electrostatic levitation (ESL) laboratory has a long history of providing materials research and thermophysical property data. The lab can measure thermophysical properties such as density, surface tension, and viscosity of liquid materials, including elements, alloys, glasses, ceramics, and oxides. Nickel-based superalloys (e.g. Inconel, Hastelloy, and Waspaloy) have many high performance applications, including turbine engines for aerospace. Superalloy parts are typically manufactured by casting and forging. These processes generate both polycrystalline and monocrystalline parts. A relatively new method of fabrication of turbine disk materials is additive manufacturing, which is typically done for aerospace parts by powder-bed methods such as selective laser melting (SLM). Accurate modeling of casting and forging, as well as additively manufacturing processes, require thermophysical properties (density, surface tension, and viscosity). The thermophysical properties of liquid nickel-based superalloys, both conventional and additively manufactured, were measured at several temperatures in both undercooled and superheated condition. Surface tension and viscosity was measured using the oscillating drop method and density and thermal expansion was measured using edge detection methods.

SanSoucie, Michael P.↗
NASA NTRS1994

Removal of Residual Chromium from Aluminum Oxide by Containerless Liquid-phase Processing

Berneuil sapphire was purified of Cr 3+ by containerless melting and processing at ca. 2550 K in high purity argon, dry air and pure oxygen. Recovered material was examined by laser induced fluorescence and Raman spectroscopy. The Cr 3+ fluorescence intensity decreased in processed specimens at rates proportional to the chromium concentration and p(O 2 ) 0.21 . The initial chromium concentration was ca. 5 ppm and decreased by factors of ca. 50, 3000, and 2x10 5 after processing for 300 seconds in argon, air and oxygen, respectively. Evidence is presented that the Cr 3+ was removed predominantly as CrO 2 (g) and not by conversion to other oxidation states of chromium in the condensed phase. A comparison of the Raman peak shifts for as-received and processed samples indicates that considerable stress was retained during containerless solidification of the highly undercooled melts.

sapphire↗
NASA NTRSDate not supplied

Disorder to Order in Interface Patterns: Thermal Noise to Limit Cycle Transition in Dendrite Sidebranch Formation

Thin sample directional solidification experiments have been carried out in the model succinonitrile-camphor system to examine the origin of secondary branches in dendrite morphologies. Thermal noise at the dendrite tip creates interface instabilities which amplify to form sidebranches. This is accepted as the primary mode of sidebranching in dendritic growth from an undercooled melt and occurs in directional solidification of dendrites. The proposed limit cycle couples the growth of the tip with the initiation of the sidebranch. Directional solidification of curved interfaces is a driven dissipative system with the potential to form a limit cycle. Two sets of experiments were performed, the first holding velocity constant and evolving the gradient and the second imposing oscillating velocities around the natural period of sidebranching. Both experimental methods were found to characterize a transition from disordered sidebranching induced by thermal noise to ordered sidebranching produced by the limit cycle mechanisms. This is the first quantitative measurement of previously hypothesized limit cycle growth. These experiment sets have been quantitatively analyzed for dynamic behavior seen in limit cycles. High-quality data sets of the tip and instability enable the measurement of the FFT and analysis through a power spectrum. At low gradients, the sidebranches are found to be excited by thermal noise far away from the tip. As the gradient increases and velocity is held constant, the distance between the instability and tip decreases until limit cycle growth is found between the tip of the primary dendrite and the first forming sidebranch. An alternative to the deterministic limit cycles seen in experiments of gradient evolution is a limit cycle actively driven through the square wave oscillation of velocity. Crucial observations of the solidified microstructure conclude that this produced periodic interconnected bridges between the primary dendrites. This is a finding with potentially significant implications for commercial applications.

Trevor Lyons↗