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NASA NTRS1985

Modification of the Electromagnetic Levitator (EML) Hardware

The goals of this project are: (1) to study the upgrade requirements and approaches needed for incorporation of an Electromagnetic Levitator (EML) into the shuttle orbiter, (2) to work with members of the Electromagnetic Containerless Processing science working group (SWG) to define future experiments for the EML, and (3) to assist these investigators in further development of ground-based experiment techniques to the limits possible in the terrestrial gravitational environment. Present work is directed toward: (1) upgrading the EML flight apparatus to meet requirements of safety and integration interfaces with the MSL orbiter carrier, (2) development of new experiment components required to carry out approved experiments in undercooled solidification and associated fluid flow studies directed by MIT, and (3) construction, test, qualification and integration assistance for the EML MSL flight package.

Frost, R. T.↗
NASA NTRS2012

Advanced Measurement Devices for the Microgravity Electromagnetic Levitation Facility EML

This paper reports on two advanced measurement devices for the microgravity electromagnetic levitation facility (EML), which is currently under construction for the use onboard the "International Space Station (ISS)": the "Sample Coupling Electronics (SCE)" and the "Oxygen Sensing and Control Unit (OSC)". The SCE measures by a contactless, inductive method the electrical resistivity and the diameter of a spherical levitated metallic droplet by evaluating the voltage and electrical current applied to the levitation coil. The necessity of the OSC comes from the insight that properties like surface tension or, eventually, viscosity cannot seriously be determined by the oscillating drop method in the EML facility without knowing the conditions of the surrounding atmosphere. In the following both measurement devices are explained and laboratory test results are presented.

Brillo, Jurgen↗
NASA NTRS2012

Thermophysical Properties Measurement of High-Temperature Liquids Under Microgravity Conditions in Controlled Atmospheric Conditions

Microgravity conditions have advantages of measurement of surface tension and viscosity of metallic liquids by the oscillating drop method with an electromagnetic levitation (EML) device. Thus, we are preparing the experiments of thermophysical properties measurements using the Materials-Science Laboratories ElectroMagnetic-Levitator (MSL-EML) facilities in the international Space station (ISS). Recently, it has been identified that dependence of surface tension on oxygen partial pressure (Po2) must be considered for industrial application of surface tension values. Effect of Po2 on surface tension would apparently change viscosity from the damping oscillation model. Therefore, surface tension and viscosity must be measured simultaneously in the same atmospheric conditions. Moreover, effect of the electromagnetic force (EMF) on the surface oscillations must be clarified to obtain the ideal surface oscillation because the EMF works as the external force on the oscillating liquid droplets, so extensive EMF makes apparently the viscosity values large. In our group, using the parabolic flight levitation experimental facilities (PFLEX) the effect of Po2 and external EMF on surface oscillation of levitated liquid droplets was systematically investigated for the precise measurements of surface tension and viscosity of high temperature liquids for future ISS experiments. We performed the observation of surface oscillations of levitated liquid alloys using PFLEX on board flight experiments by Gulfstream II (G-II) airplane operated by DAS. These observations were performed under the controlled Po2 and also under the suitable EMF conditions. In these experiments, we obtained the density, the viscosity and the surface tension values of liquid Cu. From these results, we discuss about as same as reported data, and also obtained the difference of surface oscillations with the change of the EMF conditions.

Watanabe, Masahito↗
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 NTRS2000

Turbulent Transition in Electromagnetically Levitated Drops

Electromagnetic levitation (EML) is an important tool in materials research. Because a sample can be processed without contact with a container, experiments may be performed on high temperature, highly reactive, and undercooled liquid metals. Many of these experiments are affected by fluid flow in the sample, driven by the electromagnetic positioning force. Despite the importance of convection in these experiments, the transition to turbulence is not well understood in this system. However, we have observed a transition from laminar to turbulent flow in EML droplets in the course of microgravity experiments in TEMPUS on the Space Shuttle (STS-94). The transition occurs repeatably and over a narrow range of conditions. These experimental observations are compared with two competing theories about the transition to turbulence. Also, the results of a particle tracking study of the instabilities leading up to the transition to turbulence are presented.

Hyers, Robert W.↗
NASA NTRS1999

Surface Tension and Viscosity Measurements in Microgravity: Some Results and Fluid Flow Observations during MSL-1

The viscosity of a liquid metal was successfully measured for the first time by a containerless method, the oscillating drop technique. This method also provides a means to obtain a precise, non-contact measurement of the surface tension of the droplet. This technique involves exciting the surface of the molten sample and then measuring the resulting oscillations; the natural frequency of the oscillating sample is determined by its surface tension, and the damping of the oscillations by the viscosity. These measurements were performed in TEMPUS, a microgravity electromagnetic levitator (EML), on the Space Shuttle as a part of the First Microgravity Science Laboratory (MSL-1), which flew in April and July 1997 (STS-83 and STS-94). Some results of the surface tension and viscosity measurements are presented for Pd82Si18. Some observations of the fluid dynamic characteristics (dominant flow patterns, turbulent transition, cavitation, etc.) of levitated droplets are presented and discussed together with magnetohydrodynamic calculations, which were performed to justify these findings.

Hyer, Robert W.↗
NASA NTRS2001

The Role of Convection and Growth Competition in Phase Selection in Microgravity: Controlled Convection in the Containerless Processing of Steel Alloys

Containerless processing using electromagnetic levitation (EML) is a powerful technique in the investigation of reactive molten metal systems. On ground, the power required to overcome the weight of the sample is sufficient to cause significant heating and induce substantial melt convection. In microgravity, the heating and positioning fields may be decoupled and the field strength may be varied to achieve the desired level of convection within the limits set by the geometry of the levitation coil and the sample size. From high-speed digital images of the double recalescence behavior of Fe-Cr-Ni alloys in ground-based testing and in reduced-gravity aboard the NASA KC-135 parabolic aircraft, we have shown that phase selection can be predicted based on a growth competition model. An important parameter in this model is the delay time between primary nucleation and subsequent nucleation of the stable solid within the liquid/metastable solid array. This delay time is a strong function of composition and a weak function of the undercooling of the melt below the metastable liquidus. From the results obtained during the first Microgravity Sciences Laboratory (MSL-1) mission, we also know that convection may significantly influence the delay time, especially at low undercoolings. Currently, it is unclear what mechanism controls the formation of a heterogeneous site that allows nucleation of the austenitic phase on the pre-existing ferrite skeleton. By examining the behavior of the delay time under different convective conditions, we hypothesize that we can differentiate between several of these mechanisms to gain an understanding of how to control microstructural. evolution. We will anchor these predictions by examining samples quenched at different times following primary recalescence in microgravity. A second important parameter in the growth competition model is the identification of the growth rate of the stable phase into the semi-solid array that formed during primary recalescence. Current dendritic growth theory is inadequate in predicting solidification behavior under these conditions as metallographic analyses show that stable phase growth proceeds along the interface between the metastable solid and residual liquid. Since growth velocity is independent of the initial undercooling relative to the metastable liquidus, we hypothesize that purely thermal effects can be separated from other important growth model parameters by careful selection of the liquid composition in a ternary system.

Matson, D. M.↗
NASA NTRS2003

Flight Planning for the International Space Station - Levitation Observation of Dendrite Evolution in Steel Ternary Alloy Rapid Solidification (LODESTARS)

During rapid solidification, a molten sample is cooled below its equilibrium solidification temperature to form a metastable liquid. Once nucleation is initiated, growth of the solid phase proceeds and can be seen as a sudden rise in temperature. The heat of fusion is rejected ahead of the growing dendrites into the undercooled liquid in a process known as recalescence. Fe-Cr-Ni alloys may form several equilibrium phases and the hypoeutectic alloys, with compositions near the commercially important 316 stainless steel alloy, are observed to solidify by way of a two-step process known as double recalescence. During double recalescence, the first temperature rise is associated with formation of the metastable ferritic solid phase with subsequent conversion to the stable austenitic phase during the second temperature rise. Selection of which phase grows into the undercooled melt during primary solidification may be accomplished by choice of the appropriate nucleation trigger material or by control of the processing parameters during rapid solidification. Due to the highly reactive nature of the molten sample material and in order to avoid contamination of the undercooled melt, a containerless electromagnetic levitation (EML) processing technique is used. In ground-based EML, the same forces that support the weight of the sample against gravity also drive convection in the liquid sample. However, in microgravity, the force required to position the sample is greatly reduced, so convection may be controlled over a wide range of internal flows. Space Shuttle experiments have shown that the double recalescence behavior of Fe-Cr-Ni alloys changes between ground and space EML experiments. This program is aimed at understanding how melt convection influences phase selection and the evolution of rapid solidification microstructures.

Flemings, Merton C.↗
NASA NTRS2012

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↗
NASA NTRS2018

Levitation Experiments on ISS: Science and Applications

Levitation experiments on the International Space Station (ISS) are ongoing. The European Space Agency (ESA) Materials Science Laboratory Electromagnetic Levitator (MSL-EML) has been in operation since 2015. US investigators are on several of the European Topical Teams and have been heavily involved with the experiments since 2009. The experiments include magneto-hydrodynamic (MHD) modeling of macro-convection, the effects of convection on microstructure, investigation of metallic glass formation, and much more. Recently NASA selected four proposals to the MaterialsLab NASA Research Announcement (NRA) for experiments on the Japan Aerospace eXploration Agency (JAXA) Electrostatic Levitation Furnace (ELF), which was launched to the ISS in 2015. It is estimated that the four US investigators will have flight experiments on ELF within the next few years. The experiments range from a novel method to measure interfacial tension to investigations of thermophysical properties of metals, metal oxides, and non-linear optical materials. Using the MSL-EML and ELF, US investigators are studying a wide range of NASA exploration-relevant materials. Levitation experiments enable exploration in many ways. For example, high quality thermophysical properties of high-temperature materials are critical to develop accurate models of casting, welding, and metal additive manufacturing, which could lead to more efficient and more reliable production of metallic parts for exploration, commercial, and industrial applications. High-quality thermophysical properties could also lead to the development of functional oxide glass and optical materials. In many cases, the accuracy of available property data is the limiting factor in the predictive capabilities of the models. Many thermophysical properties can be measured in a levitator on Earth, but with convective contamination. This contamination plays a significant role in the formation of the intermediate phases. In particular, nucleation and viscosity measurements demand quiescent conditions that can only be attained in microgravity-based levitation systems. A brief overview of the ongoing and planned levitation experiments on the ISS will be presented, followed by the exploration-relevance.

SanSoucie, Michael P.↗
NASA NTRS2005

Beamline Electrostatic Levitator (BESL) for in-situ High Energy K-Ray Diffraction Studies of Levitated Solids and Liquids at High Temperature

Determinations of the phase formation sequence, the crystal structures and the thermodynamic properties of materials at high temperatures are difficult because of contamination from the sample container and environment. Containerless processing techniques, such as electrostatic (ESL), electromagnetic (EML), aerodynamic, and acoustic levitation, are most suitable these studies. An adaptation of ESL for in-situ structural studies of a wide range of materials, including metals, semiconductors, insulators using high energy (125 keV) synchrotron x-rays is described here. This beamline ESL (BESL) allows the in-situ determination of the atomic structures of equilibrium solid and liquid phases, including undercooled liquids, as well as real-time studies of solid-solid and liquid-solid phase transformations. The use of image plate (MAR345) or GE-Angio detectors enables fast (30 ms - 1s) acquisition of complete diffraction patterns over a wide q-range (4 - 140/mm). The wide temperature range (300 - 2500 K), containerless processing under high vacuum (10(exp -7) - 10(exp -8) torr), and fast data acquisition, make BESL particularly suitable for phase diagram studies of high temperature materials. An additional, critically important, feature of BESL is the ability to also make simultaneous measurement of a host of thermo-physical properties, including the specific heat, enthalpy of transformation, solidus and liquidus temperatures, density, viscosity, and surface tension; all on the same sample and simultaneous with the structural measurements.

Gangopadhyay, A. K.↗
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 NTRS2012

Containerless Processing Studies in the MSFC Electrostatic Levitator

Levitation or containerless processing represents an important tool in materials research. Levitated specimens are free from contact with a container, which permits studies of deeply undercooled melts, and high-temperature, highly reactive materials. Containerless processing provides data for studies of thermophysical properties, phase equilibria, metastable state formation, microstructure formation, undercooling, and nucleation. Levitation techniques include: acoustic, aero-acoustic, electromagnetic, and electrostatic. In microgravity, levitation can be achieved with greatly reduced positioning forces. Microgravity also reduces the effects of buoyancy and sedimentation in melts. The European Space Agency (ESA) and the German Aerospace Center (DLR) jointly developed an electromagnetic levitator facility (MSL-EML) for containerless materials processing in space. The MSL-EML will be accommodated in the European Columbus Facility on the International Space Station (ISS). The electrostatic levitator (ESL) facility at the Marshall Space Flight Center provides support for the development of containerless processing studies for the ISS. The capabilities of the facility and recent results will be discussed.

Rogers, J. R.↗
NASA NTRS2012

Electrostatic Levitation: A Tool to Support Materials Research in Microgravity

Containerless processing represents an important topic for materials research in microgravity. Levitated specimens are free from contact with a container, which permits studies of deeply undercooled melts, and high-temperature, highly reactive materials. Containerless processing provides data for studies of thermophysical properties, phase equilibria, metastable state formation, microstructure formation, undercooling, and nucleation. The European Space Agency (ESA) and the German Aerospace Center (DLR) jointly developed an electromagnetic levitator facility (MSL-EML) for containerless materials processing in space. The electrostatic levitator (ESL) facility at the Marshall Space Flight Center provides support for the development of containerless processing studies for the ISS. Apparatus and techniques have been developed to use the ESL to provide data for phase diagram determination, creep resistance, emissivity, specific heat, density/thermal expansion, viscosity, surface tension and triggered nucleation of melts. The capabilities and results from selected ESL-based characterization studies performed at NASA's Marshall Space Flight Center will be presented.

Rogers, Jan↗
NASA NTRS2002

Spin-Up Instability of a Levitated Molten Drop in MHD-Flow Transition to Turbulence

When an alternating magnetic field interacts with induced eddy currents in a conducting body, there will be a repulsive force between the body and the driving coil system generating the field. This repulsive force is the basis of electromagnetic levitation, which allows containerless processing of different materials. The eddy currents in the conducting body also generate Joule heating. Axial rotation of electromagnetically levitated objects is a common observation in levitation systems and often an undesirable side effect of such experiments on 1-g and -g. There have been recent efforts to use magnetic damping and suppress this tendency of body rotation. The first report of rotation in EML drops was attributed to a slight asymmetry of the shape and location of the levitation coils could change the axis and speed of rotation. Other theories of sample rotation include a frequency difference in the traveling electromagnetic waves and a phase difference in two different applied fields of the same frequency. All of these different mechanisms share the following characteristics: the torque is small, constant for constant field strength, and very weakly dependent on the sample's temperature and phase (solid or liquid). During experiments on the MSL-1 (First Microgravity Science Laboratory) mission of the Space Shuttle (STS-83 and STS-94, April and July 1997), a droplet of palladium-silicon alloy was electromagnetically levitated for viscosity measurements. For the non-deforming droplet, the resultant MHD flow inside the drop is inferred from motion of impurities on the surface. These observations indicate formation of a pair of co-rotating toroidal flow structures inside the spheroidal levitated drop that undergo secondary flow instabilities. As rise in the fluid temperature rises, the viscosity falls and the internal flow accelerates and becomes oscillatory; and beyond a point in the experiments, the surface impurities exhibit non-coherent chaotic motion signifying emergence of turbulence inside the drop. In this work, a background of these set of observations will be given followed by a presentation of our results on the digital particle tracking analysis that has been performed on a number of available videos. The analysis indicates that the levitated drop attains a constant rotational speed during the melting phase and formation of the co-rotating axi-symmetric laminar toroidal structures. However, the rate of axial rotation increases dramatically during the deformation of the toroidal structures anti their breakup into chaotic entities. This new data suggests an interaction between the flow inside the levitated molten drop and the driving coils in the experiments. Possible mechanisms for this interaction will be reviewed. The data will also be used to make an assessment of existing theories on droplet rotation.

Abedian, B.↗
NASA NTRS2012

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.↗