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During the past years, extensive collaborative research has been done to understand phase selection in undercooled metals using novel containerless processing techniques such as electrostatic and electromagnetic levitation. Of major interest is controlling a two-step solidification process, double recalescence, in which the metastable phase forms first and then transforms to the stable phase after a certain delay time. The previous research has shown that the delay time is greatly influenced by the internal convection velocity. In the prediction of internal flow, the fidelity of the results depends on the accuracy of the material properties. This research focuses on the measurements of density and viscosity of Fe-Co alloys which will be used for the fluid simulations whose results will support upcoming International Space Station flight experiments.

The thermophysical properties of glass-forming and quasicrystal-forming alloys show many interesting features in the undercooled liquid range. Some of the features in the thermophysical property curves are expected to reflect changes in the structure and coordination of the liquid. These measurements require containerless processing such as electrostatic levitation to access the undercooled liquid regime. An overview of the state of the art in measuring the thermophysical properties and structure of undercooled liquid glass-forming and quasicrystal-forming alloys will be presented, along with the status of current measurements.

Thermophysical property studies performed at high temperature can prove challenging because of reactivity problems brought on by the elevated temperatures. Contaminants from measuring devices and container walls can cause changes in properties. To prevent this, containerless processing techniques can be employed to isolate a sample during study. A common method used for this is levitation. Typical levitation methods used for containerless processing are, aerodynamically, electromagnetically and electrostatically based. All levitation methods reduce heterogeneous nucleation sites, 'which in turn provide access to metastable undercooled phases. In particular, electrostatic levitation is appealing because sample motion and stirring are minimized; and by combining it with optically based non-contact measuring techniques, many thermophysical properties can be measured. Applying some of these techniques, surface tension, viscosity and density have been measured for the glass forming alloy Zr62Cu20Al10Ni8 and will be presented with a brief overview of the non-contact measuring method used.

State-of-the-art technologies for hypersonic aircraft, nuclear electric/thermal propulsion for spacecraft, and more efficient jet engines are driving ever more demanding needs for high-temperature (>2000 C) materials. At such high temperatures, creep rises as one of the most important design factors to be considered. Since conventional measurement techniques for creep resistance are limited to about 17OO0C, a new technique is in demand for higher temperatures. This paper presents a non-contact method using electrostatic levitation (ESL) which is applicable to both metallic and non-metallic materials. The samples were rotated quickly enough to cause creep deformation by centrifugal acceleration. The deformation of the samples was captured with a high speed camera and then the images were analyzed to estimate creep resistance. Finite element analyses were performed and compared to the experiments to verify the new method. Results are presented for niobium and tungsten, representative refractory materials at 2300 C and 2700 C respectively.

Continuing pressures for higher performance and efficiency in propulsion are driving ever more demanding needs for high-temperature materials. Some immediate applications in spaceflight include combustion chambers for advanced chemical rockets and turbomachinery for jet engines and power conversion in nuclear-electric propulsion. In the case of rockets, the combination of high stresses and high temperatures make the characterization of creep properties very important. Creep is even more important in the turbomachinery, where a long service life is an additional constraint. Some very high-temperature materials are being developed, including platinum group metals, carbides, borides, and silicides. But the measurement of creep properties at very high temperatures is itself problematic, because the testing instrument must operate at such high temperatures. Conventional techniques are limited to about 1700 C. A new, containerless technique for measuring creep deformation has been developed. This technique is based on electrostatic levitation (ESL) of a spherical sample, which is heated to the measurement temperature and rotated at a rate such that the centrifugal acceleration causes creep deformation. Creep of samples has been demonstrated at up to 2300 C in the ESL facility at NASA MSFC, while ESL itself has been applied at over 3000 C, and has no theoretical maximum temperature. The preliminary results and future directions of this NASA-funded research collaboration will be presented.

The surface tension, viscosity, density, and thermal expansion of Ti-Zr-Ni alloys were measured for a number of compositions by electrostatic levitation methods. Containerless methods greatly reduce heterogeneous nucleation, increasing access to the undercooled liquid regime at finite cooling rates. The density and thermal expansion are measured optically, while the surface tension and viscosity are measured by the oscillating drop method. The measured alloys include compositions which form a metastable quasicrystal phase from the undercooled liquid, and alloys close to the composition of several multi-component bulk metallic glass-forming alloys. Measurements of surface tension show behavior typical of transition metals at high temperature, but a sudden decrease in the deeply undercooled liquid for alloys near the quasicrystal-forming composition range, but not for compositions which form the solid-solution phase first.