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As new alloys are being developed for additive manufacturing (AM) applications, questions related to the temperature-dependent structural and compositional stability of these alloys remain. In this work, the benefits and limitations of a unique method for testing this stability are presented. This system employs the use of polychromatic synchrotron light to perform energy-dispersive x-ray diffraction (ED-XRD) on an electrostatically levitated sample at high temperatures. In comparison with a traditional angular-dispersive setup, the container-less electrostatic levitation method has unique advantages, including quicker acquisition times, simultaneous compositional information through fluorescence emissions, a reduction in background noise, and, importantly, concurrent/subsequent measurement of thermophysical properties. This combined method is ideal for phase transition studies by holding the levitated sample at a stable position and temperature through controlled heating and temperature management. To illustrate these capabilities, we show ED-XRD data of the well-known martensitic phase transition (hcp to bcc) in Ti–6Al–4V. In addition, results from the novel alloy Ni51Cu44Cr5 are presented. This alloy is shown to maintain an fcc structure upon heating. However, the concentration of Cu is reduced at high temperatures, resulting in a decrease in the lattice constant. As concurrent thermophysical properties are probed, these preliminary structure and composition experiments demonstrate the capabilities of this technique to determine the composition–processing–structure–properties of metal alloys for AM. 

Abstract The dynamics of levitated liquid droplets can be used to measure their thermophysical properties by correlating the frequencies at which normal modes of oscillation most strongly resonate when subject to an external oscillatory force. In two preliminary works, it was shown via electrostatic levitation and processing of various metals and alloys that (1) the resonance of the first principal mode of oscillation (moden = 2) can be used to accurately measure surface tension and (2) that so-called “higher-order resonance” ofn = 3 is observable at a predictable frequency. It was also shown, in the context of future space-based experimentation on the Electrostatic Levitation Furnace (ELF), a setup on the International Space Station (ISS) operated by Japan Aerospace Exploration Agency (JAXA), that while the shadow array method in which droplet behavior is visualized would be challenging to identify then = 3 resonance, the normal moden = 4 was predicted to be more easily identifiable. In this short communication, experimental evidence of the first three principal modes of oscillation is provided using molten samples of Tin and Indium and it is subsequently shown that, as predicted, an “image-less approach can be used to identify bothn = 2 andn = 4 resonances in levitated liquid droplets. This suggests that the shadow array method may be satisfactorily used to obtain a self-consistent benchmark of thermophysical properties by comparing results from two successive even-mode natural frequencies. 

Abstract The Faraday forcing method in levitated liquid droplets has recently been introduced as a method for measuring surface tension using resonance. By subjecting an electrostatically levitated liquid metal droplet to a continuous, oscillatory, electric field, at a frequency nearing that of the droplet’s first principal mode of oscillation (known as mode 2), the method was previously shown to determine surface tension of materials that would be particularly difficult to process by other means, e.g., liquid metals and alloys. It also offers distinct advantages in future work involving high viscosity samples because of the continuous forcing approach. This work presents (1) a benchmarking experimental method to measure surface tension by excitation of the second principal mode of oscillation (known as mode 3) in a levitated liquid droplet and (2) a more rigorous quantification of droplet excitation using a projection method. Surface tension measurements compare favorably to literature values for Zirconium, Inconel 625, and Rhodium, using both modes 2 and 3. Thus, this new method serves as a credible, self-consistent benchmarking technique for the measurement of surface tension.