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A method and apparatus for enhancing and shaping acoustical levitation forces in a single-axis acoustic resonance system wherein specially shaped drivers and reflectors are utilized to enhance to levitation force and better contain fluid substance by means of field shaping is described.
Methods are described for acoustically levitating objects within chambers of spherical and cylindrical shape. The wavelengths for chambers of particular dimensions are given, for generating standing wave patterns of any of a variety of modes within the chambers. For a spherical chamber the lowest resonant mode is excited by applying a wavelength of 3.02R, where R is the chamber radius. The two lowest pure radial modes for that chamber, are excited by applying wavelengths of 1.40R and 0.814R. For a cylindrical chamber of radius R, the lowest mode is at a wavelength of 3.41R, and the lowest pure radial modes are at wavelengths of 1.64R and 0.896R.
It was observed that the acoustically levitated molten SCN (succinonitrile) drops can generally be undercooled to a degree where the impurities in the drop are responsible for the nucleation of the solid phase. However, it was also observed that ultrasound occasionally terminates undercooling of the levitated drops by initiating the nucleation of the solid at an undercooling level which is lower than that found for the nucleation catalyzed by the impurities in the drop. This premature nucleation can be explained by thermodynamic considerations which predict an increase in effective undercooling of the liquid upon the collapse of cavities. Pre-existing gas microbubbles which grow under the influence of ultrasound are suggested as the source of cavitation. The highly undercooled SCN drops can be utilized to measure the growth velocity of the solid in the deeply undercooled region including the hypercooled region.
Rotation-control equipment simplified. Acoustic levitator with rotation control handles liquid and solid specimens as dense as steel in both low gravity and normal Earth gravity. Levitator is single-axis type.
Knowing the thermophysical properties of high-temperature melts can aid the design of melt processes and validate atomic structural models, such as those used in studying glass formation. Property measurements on such melts are challenging, however, due to container-related contamination and heterogeneous nucleation. Containerless processing techniques that employ levitation can be used to avoid these obstacles. In that context, we demonstrate here the application of silhouette imaging to measure the density of molten oxides in an aero-acoustic levitation instrument (AAL). The AAL combines gas jet levitation with actively controlled acoustic positioning to enable full optical access to samples ca. 2–4 mm in diameter, which are laser beam heated and melted. The cross sections of molten drops are imaged using a monochromatic light source and narrowband-filtered camera. Melt volume is calculated from the cross sections and used to find density at several temperatures ranging 1530–1920 K, including up to 350 K of supercooling. We report densities for CaAl 2 O 4 , Ca 12 Al 14 O 33 , CaSiO 3 , their Fe 2 O 3 -bearing analogs, and 83TiO 2 -17RE 2 O 3 (RE = La or Nd). These provide important benchmarks of the capabilities, measurement uncertainties, and future outlook for this technique.
Densities of liquid oxide melts with melting temperatures above 2000 °C are required to establish mixing models in the liquid state for thermodynamic modeling and advanced additive manufacturing and laser welding of ceramics. Accurate measurements of molten rare earth oxide density were recently reported from experiments with an electrostatic levitator on board the International Space Station. In this work, we present an approach to terrestrial measurements of density and thermal expansion of liquid oxides from high-speed videography using an aero-acoustic levitator with laser heating and machine vision algorithms. The following density values for liquid oxides at melting temperature were obtained: Y 2 O 3 4.6 ± 0.15; Yb 2 O 3 8.4 ± 0.2; Zr 0.9 Y 0.1 O 1.95 4.7 ± 0.2; Zr 0.95 Y 0.05 O 1.975 4.9 ± 0.2; HfO 2 8.2 ± 0.3 g/cm 3 . The accuracy of density and thermal expansion measurements can be improved by employing backlight illumination, spectropyrometry and a multi-emitter acoustic levitator.
Stabilized acoustic levitation and manipulation of dense (e.g., steel) objects of 1 cm diameter, using a high powered siren, was demonstrated in trials that investigated the harmonic content and spatial distribution of the acoustic field, as well as the effect of sample position and reflector geometries on the acoustic field. Although further optimization is possible, the most stable operation achieved is expected to be adequate for most containerless processing applications. Best stability was obtained with an open reflector system, using a flat lower reflector and a slightly concave upper one. Operation slightly below resonance enhances stability as this minimizes the second harmonic, which is suspected of being a particularly destabilizing influence.
Transducer loading characteristics allow resonance tracked at high temperature. Acoustic-levitation chamber length automatically adjusted to maintain resonance at constant acoustic frequency as temperature changes. Developed for containerless processing of materials at high temperatures, system does not rely on microphones as resonance sensors, since microphones are difficult to fabricate for use at temperatures above 500 degrees C. Instead, system uses acoustic transducer itself as sensor.
"Static" and "dynamic" methods developed for measuring mass density of acoustically levitated solid particle or liquid drop. "Static" method, unknown density of sample found by comparison with another sample of known density. "Dynamic" method practiced with or without gravitational field. Advantages over conventional density-measuring techniques: sample does not have to make contact with container or other solid surface, size and shape of samples do not affect measurement significantly, sound field does not have to be know in detail, and sample can be smaller than microliter. Detailed knowledge of acoustic field not necessary.
By suitable adjustments of amplitudes and phases of three acoustic fields in three-axis acoustic levitator, orientation of aspherical levitated object controlled, and degree of asphericity measured. Orientation-and-measurement technique used to manipulate workpieces during containerless processing or to measure approach to desired asphericity in small objects like targets for laser-fusion experiments. Several versions of technique.
Sample moved to different positions for heating and quenching. Acoustical levitation chamber selectively excited in fundamental and second-harmonic longitudinal modes to hold sample at one of three stable postions: A, B, or C. Levitated object quickly moved from one of these positions to another by changing modes. Object rapidly quenched at A or C after heating in furnace region at B.
Concave driver and reflector enhance and shape levitation forces in acoustic resonance system. Single-mode standing-wave pattern is focused by ring element situated between driver and reflector. Concave surfaces increase levitating forces up to factor of 6 as opposed to conventional flat surfaces, making it possible to suspend heavier objects.
The capability of ultrasonic levitators operating in air to perform density measurements has been demonstrated. The remote determination of the density of ordinary liquids as well as low density solid metals can be carried out using levitated samples with size on the order of a few millimeters and at a frequency of 20 kHz. Two basic methods may be used. The first one is derived from a previously known technique developed for acoustic levitation in liquid media, and is based on the static equilibrium position of levitated samples in the earth's gravitational field. The second approach relies on the dynamic interaction between a levitated sample and the acoustic field. The first technique appears more accurate (1 percent uncertainty), but the latter method is directly applicable to a near gravity-free environment such as that found in space.
The properties of a dual-temperature resonant chamber to be used for acoustical levitation and positioning have been theoretically and experimentally studied. The predictions of a first-order dissipationless treatment of the generalized wave equation for an inhomogeneous medium are in close agreement with experimental results for the temperature dependence of the resonant mode spectrum and the acoustic pressure distribution, although the measured magnitude of the pressure variations does not correlate well with the calculated one. Ground-based levitation of low-density samples has been demonstrated at 800 C, where steady-state forces up to 700 dyn were generated.
In new manufacturing process, small gas-filled polymer shells made by injecting gas directly into acoustically levitated prepolymer drops. New process allows sufficient time for precise control of shell geometry. Applications foreseen in fabrication of deuterium/tritium-filled fusion targets and in pharmaceutical coatings. New process also useful in glass blowing and blow molding.
High temperature processing of a small specimen without a container has been demonstrated in a set of experiments using an acoustic levitation furnace in the microgravity of space. This processing technique includes the positioning, heating, melting, cooling, and solidification of a material supported without physical contact with container or other surface. The specimen is supported in a potential energy well, created by an acoustic field, which is sufficiently strong to position the specimen in the microgravity environment of space. This containerless processing apparatus has been successfully tested on the Space Shuttle during the STS-61A mission. In that experiment, three samples wer successfully levitated and processed at temperatures from 600 to 1500 C. Experiment data and results are presented.
A 20 kHz single-axis acoustic positioner is used to levitate aqueous-solution drops (volumes less than or approximately equal to 100 micro-liters). Drop evaporation rates are measured under ambient, isothermal conditions for different relative humidities. Acoustic convection around the levitated sample enhances the mass loss over that due to natural convection and diffusion. A theoretical treatment of the mass flow is developed in analogy to previous studies of the heat transfer from a sphere in an acoustic field. Predictions of the enhanced mass loss, in the form of Nusselt (Sherwood) numbers, are compared with observed rages of drop shrinking. The work is part of an ESA crystal growth from levitated solution drops.
Certain chamber shapes require fewer than three acoustic drivers. Levitation at center of spherical chamber attained using only one acoustic driver. Exitation of lowest spherical mode produces asymmetric acoustic potential well.