Search

An electromagnetic levitation apparatus incorporating an electron beam for auxiliary heating and melting has been developed for experiments on containerless vacuum purification and undercooled solidification of high melting materials. Stable levitation of 10-g specimens of molten tungsten has been achieved and a variety of containerless solidification experiments is being performed, including pure polycrystalline castings and single tungsten crystals grown from the undercooled levitated melts.

A technique has been developed for fabricating electromagnetic induction coils in a reproducible manner. The process utilizes a split mandrel that can be disassembled to remove the mandrel from the coil. The technique has increased coil production rates by a factor of 8 over the freehand winding method. The success rate for producing a functional levitation coil has been increased from 50 percent to 95 percent. The levitation coil designed during this work has successfully levitated and melted a variety of alloys including Cu, Ag, Ag-Ni, Cu-Fe, Fe-C, and Nb-Ge. W was also levitated but not melted at temperatures as high as 2700 C. The highest sample melt temperature achieved was 2400 C for the Nb-Ge samples.

A high-speed video instrumentation system was used to observe solidification of undercooled Ti-51 at. pct Al. The camera system developed by Battelle is capable of operation at rates up to 12,000 frames per second. The system digitizes and stores video images acquired by a 64 x 64 pixel silicon photodiode array. In a joint effort with Vanderbilt University the camera was used to observe three transformations of the undercooled alloys, using containerless processing by electromagnetic levitation. The first was solidification where nucleation was induced at an undercooling of 9 percent Tl, where Tl is the liquidus temperature of the alloy, and the second was solidification where nucleation was spontaneous at an undercooling of 15 percent Tl. The third event was a solid-state nucleation and growth transformation following the solidification at an undercooling of 15 percent Tl.

A concept is developed and described which allows to measure the heat capacity and the effective thermal conductivity of stable and undercooled liquid metals and alloys in an electromagnetic levitation apparatus. A proposal is made to use an ac pulse heating method which is used nowadays as a standard technique for precision measurement of low-temperature heat capacities. The ideal process parameters, including the drop diameter D, temperature T, and frequency of measurement omega, can be optimized when the following relations hold for the external and internal relaxation time constants tau-1 and tau-2, respectively: omega(tau-1) greater than 10 and omega(tau-2) less than 0.1. Then, heat capacity data can be obtained with an accuracy of better than 1 percent with D about 5 to 10 mm, T between 1200 and 1800 K, and omega between 0.1 and 1 Hz for typical metals and alloys.

This paper proposes a novel method for sample positioning in containerless processing at microgravity, using a system based on pulsed lasers. The method has two attributes. First, by generating beams that cancel out vectorially, the suspended material can be heated without being accelerated, a feature that can be used in melting and heat-treatment applications. Second, the specimen can be positioned within a fairly large work space. It is emphasized that this method can service a regime unfulfilled by the other levitation methods, such as electromagnetic levitation, active magnetic suspension, acoustic levitation, of electrostatic suspension.