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At least 91 records · Page 5

A hybrid electromagnetic-acoustic levitator for the containerless processing of undercooled melts

The hybrid, acoustic-EM levitator discussed provides a small lifting force independently of its EM component by exciting an acoustic resonance that serves as a pressure node at the position of the EM-levitated specimen. The system also stabilizes and damps chaotic oscillations during specimen positioning, and can excite forced oscillations of levitated molten metals for drop-physics and thermophysical property measurements. Attention is given to the character and function of the atmosphere in the levitator. Noncontact temperature measurement is via single-color optical pyrometer.

Hmelo, Anthony B.↗

Studies of Thermophysical Properties of Metals and Semiconductors by Containerless Processing Under Microgravity

Electromagnetic levitation under microgravity provides unique opportunities for the investigation of liquid metals, alloys and semiconductors, both above and below their melting temperatures, with minimized disturbances of the sample under investigation. The opportunity to perform such experiments will soon be available on the ISS with the EML payload which is currently being integrated. With its high-performance diagnostics systems EML allows to measure various physical properties such as heat capacity, enthalpy of fusion, viscosity, surface tension, thermal expansion coefficient, and electrical conductivity. In studies of nucleation and solidification phenomena the nucleation kinetics, phase selection, and solidification velocity can be determined. Advanced measurement capabilities currently being studied include the measurement and control of the residual oxygen content of the process atmosphere and a complementary inductive technique to measure thermophysical properties.

Seidel, A.↗

Crystallographic Stability of Metastable Phase Formed by Containerless Processing in REFeO3 (RE: Rare-Earth Element)

Undercooling a melt often facilitates a metastable phase to nucleate preferentially. Although the classical nucleation theory shows that the most critical factor for forming a metastable phase is the interface free energy, the crystallographic stability is also indispensable for the phase to be frozen at ambient temperature. In compound materials such as oxides, authors have suggested that the decisive factors for forming a critical nucleus are not only the free energy difference but also the difference of the entropy of fusion between stable and metastable phases. In the present study, using REFeO3 (RE: rare-earth element) as a model material, we investigate the formation of a metastable phase from undercooled melts with respect to the competitive nucleation and crystallographical stabilities of both phases.

Kuribayashi, Kazuhiko↗

Containerless Processing on ISS: Ground Support Program for EML

EML is an electromagnetic levitation facility planned for the ISS aiming at processing and investigating liquid metals or semiconductors by using electromagnetic levitation technique under microgravity with reduced electromagnetic fields and convection conditions. Its diagnostics and processing methods allow to measure thermophysical properties in the liquid state over an extended temperature range and to investigate solidification phenomena in undercooled melts. The EML project is a common effort of The European Space Agency (ESA) and the German Space Agency DLR. The Microgravity User Support Centre MUSC at Cologne, Germany, has been assigned the responsibility for EML operations. For the EML experiment preparation an extensive scientific ground support program is established at MUSC, providing scientific and technical services in the preparation, performance and evaluation of the experiments. Its final output is the transcription of the scientific goals and requirements into validated facility control parameters for the experiment execution onboard the ISS.

Diefenbach, Angelika↗

Containerless science for materials processing

Containerless materials processing in space to restrict specimen deformation from hydrostatic pressure of contact with the container is discussed. Several containerless science studies are reviewed, including the study of drop dynamics, nucleation studies, metastable solid phases experiments, glass research, biological materials research, and protein crystal growth. The development of technologies for materials research in space are examined, including acoustic containerless systems, and electrostatic and electromagnetic containerless processing.

Wang, T. G.↗

Nial and Nial-Based Composites Directionally Solidified by a Containerless Zone Process

A containerless electromagnetically levitated zone (CELZ) process has been used to directionally solidify NiAl and NiAl-based composites. The CELZ processing results in single crystal NiAl (HP-NiAl) having higher purity than commercially pure NiAl grown by a modified Bridgman process (CP-NiAl). The mechanical properties, specifically fracture toughness and creep strength, of the HP-NiAl are superior to binary CP-NiAl and are used as a base-line for comparison with the composite materials subsequently studied. Two-phase composite materials (NiAl-based eutectic alloys) show improvement in room temperature fracture toughness and 1200 to 1400 K creep strength over that of binary HP-NiAl. Metallic phase reinforcements produce the greatest improvement in fracture toughness, while intermetallic reinforcement produces the largest improvement in high temperature strength. Three-phase eutectic alloys and composite materials were identified and directionally solidified with the intent to combine the improvements observed in the two-phase alloys into one alloy. The room temperature fracture toughness and high temperature strength (in air) serve as the basis for comparison between all of the alloys. Finally, the composite materials are discussed in terms of dominant fracture mechanism observed by fractography.

Joslin, Steven M.↗

Materials processing - A matter of gravity

The paper examines the pervasive influences of gravitational forces on processes used in the preparation of materials employed in earth-based applications and considers the knowledge and benefits which may be derived from the microgravity environment of space in improving upon these constraints. Particular attention is given to the NASA Materials Processing in Space program, which is focused on crystal growth processes, solidification processes, containerless processing, fluid and chemical processes, and bioseparation processes.

Zoller, L. K.↗

Overview of materials processing in space activity at Marshall Space Flight Center

An overview of activities involving the Space Transportation System (STS), now in the operational phase, and results of some of the current space experiments, as well as future research opportunities in microgravity environment, are presented. The experiments of the Materials Processing in Space Program flown on the STS, such as bioseparation processes, isoelectric focusing, solidification and crystal growth processes, containerless processes, and the Materials Experiment Assembly experiments are discussed. Special consideration is given to the experiments to be flown aboard the Spacelab 3 module, the Fluids Experiments System, and the Vapor Crystal Growth System. Ground-based test facilities and planned space research facilities, as well as the nature of the commercialization activities, are briefly explained.

Williams, J. R.↗

Phoretic Force Measurement for Microparticles Under Microgravity Conditions

This theoretical and experimental investigation of the collisional interactions between gas molecules and solid and liquid surfaces of microparticles involves fundamental studies of the transfer of energy, mass and momentum between gas molecules and surfaces. The numerous applications include particle deposition on semiconductor surfaces and on surfaces in combustion processes, containerless processing, the production of nanophase materials, pigments and ceramic precursors, and pollution abatement technologies such as desulfurization of gaseous effluents from combustion processes. Of particular emphasis are the forces exerted on microparticles present in a nonuniform gas, that is, in gaseous surroundings involving temperature and concentration gradients. These so-called phoretic forces become the dominant forces when the gravitational force is diminished, and they are strongly dependent on the momentum transfer between gas molecules and the surface. The momentum transfer, in turn, depends on the gas and particle properties and the mean free path and kinetic energy of the gas molecules. The experimental program involves the particle levitation system shown. A micrometer size particle is held between two heat exchangers enclosed in a vacuum chamber by means of ac and dc electric fields. The ac field keeps the particle centered on the vertical axis of the chamber, and the dc field balances the gravitational force and the thermophoretic force. Some measurements of the thermophoretic force are presented in this paper.

Davis, E. J.↗

Reluctant glass formers and their applications in optical lens design

Over ten years ago, it was shown that glasses with high index of refraction and some with low dispersion could be produced from a number of pure refractory oxides, including the lanthanides, by containerless processing. By containerless processing it is possible to minimize surface heterogeneous nucleation and produce larger glass samples of the materials than by other methods. The use of proposed high temperature containerless processing facilities in space permits the fabrication of benchmark samples of new unique glass compositions for optical property determination as well as for glass formation. It was shown that glasses with high refractive indices and large Abbe numbers can be formulated using this technology. These glasses lie in the classical forbidden region of the glass map. Preliminary study of the impact of having such unusual glasses available for the lens designer was made. Results indicate that significant improvements can be realized over the use of only conventional glasses. A cursory survey of a number of nationally recognized lens designers indicated a general agreement that such glasses would be highly desired and could be expected to lead to completely new designs as well as simplifying existing designs.

Ethridge, Edwin C.↗

TEMPUS: A facility for containerless electromagnetic processing onboard spacelab

The electromagnetic containerless processing facility TEMPUS was recently assigned for a flight on the IML-2 mission. In comparison to the TEMPUS facility already flown on a sounding rocket, several improvements had to be implemented. These are in particular related to: safety; resource management; and the possibility to process different samples with different requirements in one mission. The basic design of this facility as well as the expected processing capabilities are presented. Two operational aspects turned out to strongly influence the facility design: control of the sample motion (first experimental results indicate that crew or ground interaction will be necessary to minimize residual sample motions during processing); and exchange of RF-coils (during processing in vacuum, evaporated sample materials will condense at the cold surface and may force a coil exchange, when a critical thickness is exceeded).

Lenski, H.↗

Design analysis of levitation facility for space processing applications

Containerless processing facilities for the space laboratory and space shuttle are defined. Materials process examples representative of the most severe requirements for the facility in terms of electrical power, radio frequency equipment, and the use of an auxiliary electron beam heater were used to discuss matters having the greatest effect upon the space shuttle pallet payload interfaces and envelopes. Improved weight, volume, and efficiency estimates for the RF generating equipment were derived. Results are particularly significant because of the reduced requirements for heat rejection from electrical equipment, one of the principal envelope problems for shuttle pallet payloads. It is shown that although experiments on containerless melting of high temperature refractory materials make it desirable to consider the highest peak powers which can be made available on the pallet, total energy requirements are kept relatively low by the very fast processing times typical of containerless experiments and allows consideration of heat rejection capabilities lower than peak power demand if energy storage in system heat capacitances is considered. Batteries are considered to avoid a requirement for fuel cells capable of furnishing this brief peak power demand.

Frost, R. T.↗

Machine Vision for High Precision Volume Measurement Applied to Levitated Containerless Materials Processing

By combining the best practices in optical dilatometry with new numerical methods, a high-speed and high precision technique has been developed to measure volume of levitated, containerlessly processed samples with sub- pixel resolution. Containerless processing provides the ability to study highly reactive materials without the possibility of contamination affecting thermo-physical properties. Levitation is a common technique used to isolate a sample as it is being processed. Noncontact optical measurement of thermo-ophysical properties is very important as traditional measuring methods cannot be used. Modern, digitally recorded images require advanced numerical routines to recover the sub-pixel locations of sample edges and, in turn produce high precision measurements.

Bradshaw, R. C.↗

Containerless automated processing of intermetallic compounds and composites

An automated containerless processing system has been developed to directionally solidify high temperature materials, intermetallic compounds, and intermetallic/metallic composites. The system incorporates a wide range of ultra-high purity chemical processing conditions. The utilization of image processing for automated control negates the need for temperature measurements for process control. The list of recent systems that have been processed includes Cr, Mo, Mn, Nb, Ni, Ti, V, and Zr containing aluminides. Possible uses of the system, process control approaches, and properties and structures of recently processed intermetallics are reviewed.

Johnson, D. R.↗

Formation of a metastable ferromagnetic tau phase during containerless melt processing in Mn-Al-C alloys

This paper reports the production of a metastable ferromagnetic tau phase directly from the melt in Mn(0.55)Al(0.433)C(0.017), using a containerless processing method involving levitation melting followed by quenching. Using the results from differential thermal analysis measurements and an analysis of the phase equilibria, it was found that the minimum amount of undercooling level required for ferromagnetic metastable tau phase formation in this alloy was Delta T = 87 K. The attainment of this undercooling may be facilitated by the application of containerless melt processing.

Kim, Y. J.↗