Jannatun Nawer

Evaporation control is a critical facility resource during solidification experiments that limits processing time and must be tracked to ensure facility health. A thermodynamic analysis was performed on a ternary FeCrNi sample processed onboard the International Space Station (ISS) using ESA Electromagnetic Levitation (EML) facility in a microgravity environment. A non-ideal solution-based mathematical model was applied for the overall sample mass loss prediction during this study. The overall sample mass loss prediction is consistent with the post-flight mass loss measurements. The species-specific findings from this study were validated using post-mission SEM-EDX surface evaluations by three different facilities. The bulk composition prediction was validated using SEM-EDX and wet chemical analysis. The non-ideal solution model was then applied to predict the composition of the dust generated during EML testing. The thicknesses of the deposited layer on the EML coil at various locations were also calculated using the geometry of the facility and results were validated with near-real-time dust layer predictions from toxicity tracking software developed by the German Space Center (DLR) Microgravity User Support Center (MUSC).

A study of uncertainty analysis was conducted on four key thermophysical properties of molten Platinum using a non-contacting levitation technique. More specifically, this work demonstrates a detailed reporting of the uncertainties associated with the density, volumetric thermal expansion coefficient, surface tension and viscosity measurements at higher temperatures for a widely used refractory metal, Platinum using electrostatic levitation (ESL). The microgravity experiments were conducted using JAXA’s Electrostatic Levitation Furnace (ELF) facility on the International Space Station and the terrestrial experiments were conducted using NASA’s Marshal Space Flight Center’s ESL facility. The performance of these two facilities were then quantified based on the measurement precision and accuracy using the metrological International Standards Organization’s Guide to the Expression of Uncertainty Measurement (GUM) principles.

A new method for quantifying facility performance has been discussed in this study that encompasses uncertainties associated with thermophysical property measurement. Four key thermophysical properties: density, volumetric thermal expansion coefficient, surface tension, and viscosity of liquid Au have been measured in microgravity environment using two different levitation facilities. Levitation experiments were conducted using the Electrostatic Levitation Furnace (ELF) onboard the ISS in Argon and air, and the TEMPUS Electromagnetic Levitation (EML) facility on a Novespace Zero-G aircraft parabolic flight in Argon. The traditional Maximum Amplitude method was augmented through the use of Frequency Crossover method to identify the natural frequency for oscillations induced on a molten sample during Faraday forcing in ESL. The EML tests were conducted using a pulse excitation method where two techniques, one imaging and one non-imaging, were used to study surface oscillations. The re...

Density, thermal expansion coefficient, surface tension and viscosity of Ni-based CMSX-4� Plus have been measured for a range of liquid temperature by utilizing two Electrostatic levitation (ESL) facilities. Ground-based tests were conducted using the NASA MSFC ESL facility in Ultra High Vacuum and space-based tests were conducted using JAXA ELF in a 172 kPa Argon gas atmosphere. The measured values were compared to the available literature data from various other facilities. This study focuses on a detailed uncertainty analysis of the experimental data to measure the accuracy and precision of the measured properties using Guide to the expression of Uncertainty Measurement (GUM) principles. The findings from this study have been used to quantify the performance of the two ESL facilities.

Density, thermal expansion coefficient, surface tension and viscosity of liquid Zr at high temperatures were measured by oscillating droplet method in two Electrostatic Levitation (ESL) facilities. The ground-based tests at NASA MSFC ESL were conducted in vacuum and the space-based tests at JAXA ELF were conducted in Argon atmosphere with both results reported as a function of temperature. The accuracy and precision of each set of the measurement techniques has been reported using a detailed uncertainty analysis on both facilities. The uncertainties associated with each measurement were used to characterize performance for each facility. Zr samples processed in microgravity showed heavy influence of oxidation which lowered the natural frequency and thus significantly affecting the accuracy of surface tension measurement. The ground-based results are comparable to previously reported literature values.

Conducting experiments in an inert shielding-gas environment limits the likelihood for experiencing significant mass loss or compositional shifts due to differential relative evaporation. Species-specific evaporation is proven to be below prescribed limits and near-real time monitoring of the potential for exposure is shown to be an effective tool to ensure astronaut safety. The activity coefficients for key constituents in the alloy are defined as a function of temperature for inclusion in next-generation toxicity tracking software.

During containerless processing, the oscillating drop method can be used to measure the surface tension and viscosity of a levitated melt. Through containerless processing, reactive melts that cannot be measured through conventional methods can be accurately measured; however, the accuracy of this method is dependent on the internal flow within the drop. While laminar flow does not redistribute the momentum of the oscillations, turbulent flow does redistribute the momentum of the flow and, as a result, dominates the damping. As a result, it is important to understand the internal flow behavior and the factors that affect the flow during these experiments. Models are used for the indirect quantification and characterization of the internal flow using the experimental parameters and material properties. In some cases, such as Cu50Zr50, the flow is laminar over the full range of the experiment. In other cases, including Al75Ni25, the sample is dominated by turbulent flow at high temper...

Loss of mass due to evaporation during molten metal levitation processing significantly influences the evaluation of density, viscosity and surface tension during thermophysical property measurement. Since there is no direct way to track the evaporation rate during the process, this paper describes a mathematical approach to track mass loss and quantify any changes in alloy composition as a function of time and temperature. The Ni-based super alloy CMSX-4 Plus (SLS) was investigated and a model was developed to predict the dynamic loss of mass with time and track the potential for composition shifts throughout each thermal cycle based on the Langmuir’s equation for ideal solution behavior. Results were verified by post-test chemical analysis of key elemental constituents including Al, Cr, Ti, and Co where the error in composition for each element was less than 1% when the activity of aluminum in solution was fixed at zero – effectively eliminating evaporation of aluminum for ground-...

Electromagnetic levitation experiments in space are an essential tool for thermophysical property measurement and solidification studies. In light of the need for material properties as inputs to industrial process modeling, investigators need new tools for efficient experiment planning. MHD surrogate modeling is a parametric method for prediction of flow conditions during processing using the ISS-EML facility. Flow conditions in model Au, Zr, and Ti39.5Zr39.5Ni21 samples are predicted using the surrogate model. For Au, flow is shown be turbulent in nearly all experimental conditions, making property measurement difficult. For Zr, the flow is turbulent with the heater on and laminar with the heater off, allowing for property measurement during free-cooling experiments only. For TiZrNi, the flow is laminar under all experimental conditions, indicating that TiZrNi is an excellent candidate for EML experiments. This surrogate modeling approach can be easily applied to other materials o...

Conducting experiments in an inert shielding-gas environment limits the
likelihood for experiencing significant mass loss or compositional shifts due to
differential relative evaporation. Species-specific evaporation is proven to be below prescribed limits and near-real time monitoring of the potential for exposure is shown to be an effective tool to ensure astronaut safety. The activity coefficients for key constituents in the alloy are defined as a function of temperature for inclusion in next-generation toxicity tracking software.

Electromagnetic levitation experiments in space are an essential tool for thermophysical property measurement and solidification studies. In light of the need for material properties as inputs to industrial process modeling, investigators need new tools for efficient experiment planning. MHD surrogate modeling is a parametric method for prediction of flow conditions during processing using the ISS-EML facility. Flow conditions in model Au, Zr, and Ti 39.5 Zr 39.5 Ni 21 samples are predicted using the surrogate model. For Au, flow is shown be turbulent in nearly all experimental conditions, making property measurement difficult. For Zr, the flow is turbulent with the heater on and laminar with the heater off, allowing for property measurement during free-cooling experiments only. For TiZrNi, the flow is laminar under all experimental conditions, indicating that TiZrNi is an excellent candidate for EML experiments. This surrogate modeling approach can be easily applied to other materials of interest, enabling investigators to choose materials that will perform well in levitation and to tailor experiment parameters to achieve desirable flow conditions. npj Microgravity (2020) 6:9 ; https://doi.

Loss of mass due to evaporation during molten metal levitation processing significantly influences the evaluation of density, viscosity and surface tension during thermophysical property measurement. Since there is no direct way to track the evaporation rate during the process, this paper describes a mathematical approach to track mass loss and quantify any changes in alloy composition as a function of time and temperature. The Ni-based super alloy CMSX-4 Plus (SLS) was investigated and a model was developed to predict the dynamic loss of mass with time and track the potential for composition shifts throughout each thermal cycle based on the Langmuir's equation for ideal solution behavior. Results were verified by post-test chemical analysis of key elemental constituents including Al, Cr, Ti, and Co where the error in composition for each element was less than 1 % when the activity of aluminum in solution was fixed at zero-effectively eliminating evaporation of aluminum for ground-based elec-trostatic levitation (ESL) testing in vacuum. This model predicts the mass evaporation for Al and Co within ± 6 % errors for CMSX-4 plus samples processed in ESL. Application of this technique to the space tests using the ESA ISS-EML facility shows that by conducting experiments in an inert shielding-gas environment, composition shifts due to differential relative evaporation become negligible and the composition is maintained within the desired limits. By tracking overall mass loss during testing the influence of evaporation on density measurements is discussed.

The modern jet transport is considered as one of the finest integration of technologies. Its economic success depends on performance, low maintenance costs and high passenger appeal and design plays a vital role in summing up all these factors. Conceptual design is the first step to design of an aircraft. In this paper a business jet aircraft is designed to carry 8 passengers and to cover a range of 2000 NM with maximum Mach No of 0.7 and with maximum ceiling of 29,000 ft. The conceptual design consisted of initial sizing, aerodynamics and performance analysis. Through trade studies and comparison with other business jet aircrafts a final model of the aircraft was built to achieve the requirements.

Increasing usage of Nickel-based super alloys in aerospace, power plant and nuclear reactors has made it necessary to model fluid flow during casting process. It is crucial to measure thermo-physical properties of these alloys accurately for this modelling purpose. Ni-based single crystal super alloy CMSX-4 plus were investigated for mass evaporation to analyze the mass loss using Electro Static Levitation (ESL) method. Two models were developed to predict the mass loss & dynamic mass during each thermal cycle. The first model predicts the rate of mass evaporation in ideal case where the evaporation is maximum with a correction factor. The second model predicts the mass evaporation with a correction of Aluminum activity which was calculated by evaluating the results from elemental analysis for Al, Cr, Ti, and Co. Both the models were applied and compared with the data obtained from another super alloy CMSX-10K using ESL. The models were also applied to CMSX-10K processed in Electro Magnetic Levitation (EML) to compare its accuracy for different sample size. Both models are not viable for analyzing space data yielding significant error. The 2nd model predicts the mass evaporation for Al & Co within ±6 % errors for CMSX-4 plus samples processed in ESL.