Showing papers on "Liquid metal published in 2010"

Experimental modeling of the continuous casting process of steel using low melting point metal alloys - the LIMMCAST program

Abstract: This paper presents the new experimental facility LIMMCAST which was designed for modeling fluid flow and transport processes in the continuous casting of steel. The facility operates at temperatures of 200–400°C by using the low melting point alloy SnBi. The main parameters of the facility, including the dimensions of the test sections, will be given. The resultant possibilities with respect to flow investigations in the tundish, in the submerged entry nozzle, and in the mould will be discussed. Over the period of assembling and commissioning the LIMMCAST facility, the small-scale set-up Mini-LIMMCAST was employed which uses the alloy GaInSn that is liquid at room temperatures. At this precursory facility an experimental program was started which is focused on quantitative flow measurements in the mould and in the submerged entry nozzle (SEN). The Ultrasound Doppler Velocimetry (UDV) and the Contactless Inductive Flow Tomography (CIFT) were applied to determine the flow structure within the mould. First experimental results will be presented here for a single and a two-phase flow in which argon gas bubbles were injected at the inlet of the SEN. According to the concept of the electromagnetic brake the impact of a DC magnetic field on the emergent jet flow from the SEN has been studied.

Design of Practical Liquid Metal Cooling Device for Heat Dissipation of High Performance CPUs

Abstract: Broad societal needs have focused attention on technologies that can effectively dissipate huge amount of heat from high power density electronic devices. Liquid metal cooling, which has been proposed in recent years, is fast emerging as a novel and promising solution to meet the requirements of high heat flux optoelectronic devices. In this paper, a design and implementation of a practical liquid metal cooling device for heat dissipation of high performance CPUs was demonstrated. GaInSn alloy with the melting point around 10°C was adopted as the coolant and a tower structure was implemented so that the lowest coolant amount was used. In order to better understand the design procedure and cooling capability, several crucial design principles and related fundamental theories were demonstrated and discussed. In the experimental study, two typical prototypes have been fabricated to evaluate the cooling performance of this liquid metal cooling device. The compared results with typical water cooling and commercially available heat pipes show that the present device could achieve excellent cooling capability. The thermal resistance could be as low as 0.13°C/W, which is competitive with most of the latest advanced CPU cooling devices in the market. Although the cost (about 70 dollars) is still relatively high, it could be significantly reduced to less than 30 dollars with the optimization of flow channel. Considering its advantages of low thermal resistance, capability to cope with extremely high heat flux, stability, durability, and energy saving characteristic when compared with heat pipe and water cooling, this liquid metal cooling device is quite practical for future application.

Modelling of Kelvin–Helmholtz instability and splashing of melt layers from plasma-facing components in tokamaks under plasma impact

Abstract: Plasma-facing components (PFCs) in tokamaks are exposed to high-heat loads during abnormal events such as plasma disruptions and edge-localized modes. The most significant erosion and plasma contamination problem is macroscopic melt splashes and losses from metallic divertor plates and wall materials into core plasma. The classical linear stability analysis is used to assess the initial conditions for development and growth of surface waves at the plasma–liquid metal interface. The maximum velocity difference and critical wavelengths are predicted. The effects of plasma density, surface tension and magnetic field on the stability of plasma–liquid tungsten flows are analytically investigated. The numerical modelling predicts that macroscopic motion and melt-layer losses involve the onset of disturbances on the surface of the tungsten melt layer with relatively long wavelengths compared with the melt thickness, the formation of liquid tungsten ligaments at wave crests and their elongation by the plasma stream with splitting of the bulk of the melt, and the development of extremely long, thin threads that eventually break into liquid droplets. Ejection of these droplets in the form of fine spray can lead to significant plasma contamination and enhanced erosion of PFCs. The numerical results advance the current understanding of the physics involved in the mechanism of melt-layer breakdown and droplet generation processes. These findings may also have implications for free surface liquid metal flows considered as the first wall in the design of several types of future fusion reactors.

Characterization of liquid-metal Galinstan® for droplet applications

Abstract: We report our characterization of nontoxic liquid-metal alloy Galinstan® on its potential for substituting mercury droplets in miniature devices. To combat the super fast oxidation, which has been hindering the studies of Galinstan® our entire experiments are performed in a nitrogen-filled glove box. Galinstan® droplets are found to behave like a true liquid, indicating a good liquid-air interface, only if the oxygen traces stay below 1 ppm. Surface tension of Galinstan® is measured to be 534.6±±10.7 mN/m in nitrogen at 28°C using a pendant drop method. Advancing/receding contact angles on glass and Teflon surfaces are found to be 146.8°/121.5° and 161.2°/144.4°, respectively. The electrowetting on dielectric (EWOD) mechanism of Galinstan® is also demonstrated.

Spreading of liquid AuSi on vapor-liquid-solid-grown Si nanowires.

Abstract: Vapor−liquid−solid growth of high-quality Si nanowires relies on the stability of the liquid metal seed. In situ transmission electron microscopy shows that liquid AuSi seed spreads along the sidewalls of Si nanowires for some growth conditions. This liquid thin film phase separates to form solid Au clusters as the nanowire is quenched below the solidus temperature. The length that the liquid film spreads from the seed and its thickness can be explained by considering the spreading thermodynamics of droplets on cylinders.

Hybrid liquid metal-water cooling system for heat dissipation of high power density microdevices

Abstract: The recent decades have witnessed a remarkable advancement of very large scale integrated circuits (VLSI) and electronic equipments in micro-electronic industry. Meanwhile, the ever increasing power density of microdevices leads to the tough issue that thermal management becomes rather hard to solve. Conventional water cooling is widely used, but the convective coefficient is not high enough. Liquid metal owns much higher convective coefficient and has been identified as an effective coolant recently, but the high cost greatly precludes its large scale utilization. In this paper, a hybrid liquid metal–water cooling system which combines the advantages of both water and liquid metal cooling was proposed and demonstrated. By utilizing a liquid metal “heat spreader” in front of the water cooling module, this system not only owns more excellent cooling capability than that based on water alone, but also has much lower initial cost compared with absolute liquid metal cooling system. A series of experiments under different operation conditions have been performed to evaluate the cooling performance of this hybrid system. The compared results with absolute water cooling and liquid metal cooling system showed that the cooling capability of the new system is competitive with absolute liquid metal cooling, but the initial cost could be much lower. The theoretical thermal resistance model and economic feasibility also have been analyzed and discussed, which shows that the hybrid liquid metal–water cooling system is quite feasible and useful.

Single-magnet rotary flowmeter for liquid metals

Abstract: We present a theory of single-magnet flowmeter for liquid metals and compare it with experimental results. The flowmeter consists of a freely rotating permanent magnet, which is magnetized perpendicularly to the axle it is mounted on. When such a magnet is placed close to a tube carrying liquid metal flow, it rotates so that the driving torque due to the eddy currents induced by the flow is balanced by the braking torque induced by the rotation itself. The equilibrium rotation rate, which varies directly with the flow velocity and inversely with the distance between the magnet and the layer, is affected neither by the electrical conductivity of the metal nor by the magnet strength. We obtain simple analytical solutions for the force and torque on slowly moving and rotating magnets due to eddy currents in a layer of infinite horizontal extent. The predicted equilibrium rotation rates qualitatively agree with the magnet rotation rate measured on a liquid sodium flow in stainless steel duct.

Phases and Structure Characteristics of the Near Eutectic Al-Sl-Cu Alloy Using Derivative Thermo Analysis

Abstract: For determining of the micro-structural changes taking place in a near eutectic Al-Si-Cu aluminium cast alloy during heating and cooling process the UMSA device (Universal Metallurgical Simulator and Analyzer) was used. In this work the dependence between the regulated cooling speed and structure on the basis of the thermo-analysis was carried out. The thermal analysis was performed at a cooling rate in a range of 0,2 °C to 1,25 °C. The changes were examined and evaluated qualitatively by optical and electron scanning microscopy methods and the EDS microanalysis. During the investigation the formation of aluminium reach (α-Al) dendrites was revealed and also the occurrence of the α+β eutectic, the ternary eutectic α+Al2Cu+β, as well a iron and manganese containing phase was confirmed. The performed investigation are discussed for the reason of an possible improvement of thermal and structural properties of the alloy. The achieved results can be used for liquid metal processing in science and industry – for example foundry for developing and obtaining of a required alloy microstructure and properties influenced by a proper production conditions.

Reversible hydride thermal energy storage cell optimized for solar applications

Abstract: A solar energy collection and storage system and a method of collecting and storing solar energy. The system includes a device for focusing solar energy onto a reaction chamber for the conversion of metal hydride to liquid metal and hydrogen, a metal/metal hydride chamber containing a metal/metal hydride mixture, a hydrogen storage system using hydrides and a thermo-cline for recovering the thermal energy from the hydrogen when it is cooled from 2000 F to ambient conditions for storage.

Molecular-dynamic simulation of the thermophysical properties of liquid uranium

Abstract: The procedure for the calculation of the embedded atom model (EAM) potential, which involves the use of data on the structure of liquid metal in the vicinity of the melting temperature and of the results of impact tests, is applied to uranium. The use of the method of molecular dynamics and of the EAM potential produces good agreement with experiment as regards the structure, density, and potential energy of liquid metal at temperatures up to 5000 K, as well as along the shock adiabat up to pressures of ≈360 GPa. The thermodynamic properties of solid (bcc) and liquid uranium are determined at pressures up to 470 GPa and temperatures up to 12 000 K. The predicted value of bulk modulus of liquid at 1406 K is close to the actual value. The self-diffusion coefficient under isobaric heating increases with temperature by the power law with exponent of ≈2.103. The Stokes—Einstein relation is used to determine the dynamic viscosity at temperatures up to 6000 K. The obtained potential is not quite adequate for describing crystalline uranium under normal conditions. The melting temperature of uranium with EAM potential is equal to 1455 ± 2 K and somewhat higher than real. The melting temperature monotonically increases with pressure and reaches the value of 7342 K at 444 GPa. For obtaining agreement with experimental data for energy of uranium along the p = 0 isobar, it is assumed that an additional contribution to energy emerges at elevated temperatures, which is due to excitation of atomic electrons and leads to a high heat capacity: it may be as high as almost 100 kJ/mol at 5000 K. This contribution further causes a high heat capacity of highly compressed states of uranium.

Modeling of thermodiffusion in liquid metal alloys

Abstract: In this paper following the linear non-equilibrium thermodynamics approach, an expression is derived for the calculation of the thermodiffusion factor in binary liquid metal alloys. The expression is comprised of two terms; the first term accounts for the thermally driven interactions between metal ions, a phenomenon similar to that of the non-ionic binary mixtures, such as hydrocarbons; the second term is called the electronic contribution and is the mass diffusion due to an internal electric field that is induced as a result of the imposed thermal gradient. Both terms are formulated as functions of the net heats of transport. The ion–ion net heat of transport is simulated by the activation energy of viscous flow and the electronic net heat of transport is correlated with the force acting on the ions by the rearrangement of the conduction electrons and ions. A methodology is presented and used to estimate the liquid metal properties, such as the partial molar internal energies, enthalpies, volumes and the activity coefficients used for model validation. The prediction power of the proposed expression along with some other existing thermodiffusion models for liquid mixtures, such as the Haase, Kempers, Drickamer and Firoozabadi formulas are examined against available experimental data obtained on ground or in microgravity environment. The proposed model satisfactorily predicts the thermodiffusion data of mixtures that are composed of elements with comparable melting points. It is also potentially and qualitatively able to predict a sign change in thermodiffusion factor of Na–K liquid mixture. With some speculation, the sign change is attributed to an anomalous change in thermoelectric power of Na–K mixture with composition.

Development of a MEMS digital accelerometer (MDA) using a microscale liquid metal droplet in a microstructured photosensitive glass channel

Abstract: This paper introduces the operational concept, fabrication and experimental validation of a microelectromechanical systems (MEMS) digital accelerometer (MDA) that consists of a microscale (∼350 nL) liquid metal droplet in a microstructured channel etched into photosensitive glass. The MDA exploits not only the liquid metal droplet's high surface tension, high density and electrical conductivity, but also the photosensitive glass's mechanical stability and capacity to be photo-etched anisotropically. Photo-etching is used to etch an anisotropic channel into the device. During the etching process, microstructures form uniformly on the glass channel surface; they minimize contact angle hysteresis and allow the liquid metal droplet to move easily on the glass surface. By integrating the liquid metal droplet as a proof-mass to measure an input acceleration inside the microstructured photosensitive glass channel, a simple yet effective digital accelerometer is realized.

A novel approach to determine high temperature wettability and interfacial reactions in liquid metal/solid interface

Abstract: In many technical processes, high temperature wetting of a liquid metal phase on a solid substrate occurs via an extensive chemical reaction and the formation of a new solid compound at the interface. For instance, good adhesion of the zinc coating to the steel surface is one of the most important requirements that the hot-dip galvanizing process has to fulfill. Good adhesion directly depends on the formation of a defect-free Fe2Al5 inhibition layer at the interface. The complex surface chemistry of oxides on the steel surface which is a result of segregation and selective oxidation upon recrystallization annealing significantly influences the kinetics of the correlated reactive wetting. This article presents the development of a novel advanced technique for the investigation of high temperature wetting process up to a temperature of 1100 K and provides first new insights in the mechanisms of the reactive wetting process in presence of oxides on the surface. The method is based on the sessile drop method with an additional spinning technique to get rid off the liquid metal phase at any chosen wetting time, thusly opening the way to access the interfacial reaction layer directly. The presented work focuses on model alloys of interest which are mainly relevant to the industrial steel grades. Emphasis is put both on the wettability of liquid Zn and on the interfacial reactions during reactive wetting process. Insights into such reactive phenomena are fundamental demand to improve the hot-dip galvanizability of advanced high strength steel grades.

Liquid Metal Walls, Lithium, And Low Recycling Boundary Conditions In Tokamaks

Abstract: At present, the only solid material believed to be a viable option for plasma‐facing components (PFCs) in a fusion reactor is tungsten. Operated at the lower temperatures typical of present‐day fusion experiments, tungsten is known to suffer from surface degradation during long‐term exposure to helium‐containing plasmas, leading to reduced thermal conduction to the bulk, and enhanced erosion. Existing alloys are also quite brittle at temperatures under 700°C. However, at a sufficiently high operating temperature (700 – 1000 °C), tungsten is self‐annealing and it is expected that surface damage will be reduced to the point where tungsten PFCs will have an acceptable lifetime in a reactor environment.The existence of only one potentially viable option for solid PFCs, though, constitutes one of the most significant restrictions on design space for DEMO and follow‐on fusion reactors. In contrast, there are several candidates for liquid metal‐based PFCs, including gallium, tin, lithium, and tin‐lithium eutecti...

Retrograde Melting and Internal Liquid Gettering in Silicon

Abstract: COMMUNICATION Retrograde Melting and Internal Liquid Gettering in Silicon By Steve Hudelson , Bonna K. Newman , Sarah Bernardis , David P. Fenning , Mariana I. Bertoni , Matthew A. Marcus , Sirine C. Fakra , Barry Lai , and Tonio Buonassisi * Control of metal impurities has proven essential for developing modern semiconductor-based materials and devices. The prop- erties of high-performance integrated circuit, photovoltaic, and thermoelectric devices are tailored by the intentional introduc- tion of dopant species, as well as the removal and passivation of detrimental impurities. [ 1 , 2 ] In addition, the speed and uni- formity of several common semiconductor growth methods, including bulk crystal and vapor-liquid-solid (VLS) growth, are regulated by impurity-semiconductor interactions. [ 3 , 4 ] Precise control over impurity chemical states and spatial distributions requires a deep fundamental understanding of the thermodynamics and kinetics regulating impurity phase and transport. Impurity engineering in semiconductors typi- cally involves thermal annealing, as impurity solubility and diffusivity increase exponentially with temperature. However, because of the lack of suitable analytical tools for studying sub-micron-scale distributions of fast-diffusing impurities at elevated temperatures, the vast majority of experimental inves- tigations so far have been conducted at room temperature. As a result, much remains to be explored concerning fundamental impurity-semiconductor reactions at realistic processing temperatures. It was recently proposed [ 5 ] that certain silicon-impurity sys- tems can undergo melting upon cooling, a phenomenon known as retrograde melting . The controlled creation of liquid metal- silicon droplets within or on the surface of a silicon matrix of arbitrary shape could provide novel opportunities to engineer semiconductor-based systems via solid-liquid and vapor-liquid segregation. The phenomenon of retrograde melting, whereby a liquid phase forms from a solid phase upon cooling , has been observed and studied in several organic and inorganic systems, including Fe-Zr [ 6 ] and Mg-Fe-Si-O. [ 7 ] One common pathway [ ∗ ] S. Hudelson, [+] Dr. B. K. Newman, S. Bernardis, D. P. Fenning, Dr. M. I. Bertoni, Prof. T. Buonassisi Massachusetts Institute of Technology Cambridge, Massachusetts, 02139 (USA) E-mail: buonassisi@mit.edu Dr. M. A. Marcus, S. C. Fakra Advanced Light Source Lawrence Berkeley National Laboratory Berkeley, California, 94720 (USA) Dr. B. Lai Advanced Photon Source Argonne National Laboratory Argonne, Illinois, 60439 (USA) [ + ] Present address: 1366 Technologies, Lexington, MA 02421, USA for this process to occur is via the catatectic reaction, occur- ring at an invariant point on a binary phase diagram involving transformation from Solid → Solid + Liquid. [ 8 ] Many binary sys- tems exhibit such an invariant point, [ 9 ] including Ag-In, Cu-Sn, Fe-Mn, and Fe-S, [ 10 ] but very few are semiconducting mate- rials. [ 11 ] Retrograde melting in most common silicon-impurity systems cannot occur by this pathway, as these systems do not possess a catatectic point. [ 11 ] A second pathway for retrograde melting has been observed in the ternary Sb-Bi-Te system, wherein decreasing solubility of Te in Sb 2 Te 3 with decreasing temperature can lead to supersat- uration of Te and formation of liquid droplets at temperatures above the eutectic temperature. [ 12 ] We propose that a similar pathway could also produce retrograde melting in binary semiconductor-impurity systems that exhibit retrograde solu- bility. Due to the high enthalpy of formation of point defects in certain semiconductors, the solid solubility of an impu- rity within the crystal structure increases with temperature, reaching a maximum well above the eutectic temperature. Many dissolved elements in silicon demonstrate this property, [ 13 ] including many of the 3d transition metals such as iron, copper, and nickel. [ 14 ] It is hypothesized that retrograde solubility can lead to retrograde melting, [ 5 ] if supersaturation occurs at a tem- perature above the eutectic temperature (as demonstrated in Figure 1 a ). To study temperature-dependent silicon-impurity reactions at the micro-scale, we carried out synchrotron-based hard X-ray microprobe experiments at high temperatures (up to 1500 ° C). We adapted an in situ microscope hot stage (Linkam TS1500) at beamlines 10.3.2 at the Advanced Light Source [ 15 ] and 2-ID-D at the Advanced Photon Source. [ 16 ] X-ray fluorescence microscopy ( μ -XRF) mapping was used to investigate the spatial distribu- tion of transition metal-rich particles as small as 50 nm [ 17 , 18 ] in silicon matrices. The chemical state of precipitated impurities detected by μ -XRF was determined by X-ray absorption micro- spectroscopy ( μ -XAS). [ 18 ] To verify that μ -XAS can distinguish between liquid and solid phases in metal-Si systems, we prepared a standard sample (see Experimental , sample 1) consisting of a thin layer ( ∼ 1 μ m) of e-beam evaporated Cu, Ni, and Fe sandwiched between a mc-Si wafer and a thin piece ( < 15 μ m) of monocrys- talline Czochralski Si (CZ-Si). The sample was then heated to 1045 ° C, well above the Cu-Si and Ni-Si eutectic temperatures, to ensure a liquid metal-silicon mixture. μ -XRF mapping of the standard at 1045 ° C revealed that the previously continuous film had dewetted, suggesting the presence of a high-temperature liquid state. After cooling the sample to room temperature, a visual inspection revealed that the Si cap layer was fused to the

Rotational rheometry of liquid metal systems: Measurement geometry selection and flow curve analysis

Abstract: In the present study, a rotational measurement technique was used to evaluate viscosities of liquid metals and metallic alloys. Three types of measurement geometries in a high temperature rotational rheometer were evaluated: cone and plate, DIN coaxial, and double concentric cylinder (DCC). The DCC geometry proved to be the most effective. An analytical solution has been presented to evaluate the viscosity as a function of shear rate for DCC geometry. The flow curves and shear viscosities of pure Al, pure Zn and Sn95.8Ag3.28Cu0.92 solder alloy have been evaluated as a function of shear rate and melt superheat temperature. It is proposed that liquid metal systems are non-Newtonian and strongly shear thinning in flow behavior.

Description of an aerodynamic levitation apparatus with applications in Earth sciences

Abstract: In aerodynamic levitation, solids and liquids are floated in a vertical gas stream. In combination with CO2-laser heating, containerless melting at high temperature of oxides and silicates is possible. We apply aerodynamic levitation to bulk rocks in preparation for microchemical analyses, and for evaporation and reduction experiments. Liquid silicate droplets (~2 mm) were maintained stable in levitation using a nozzle with a 0.8 mm bore and an opening angle of 60°. The gas flow was ~250 ml min-1. Rock powders were melted and homogenized for microchemcial analyses. Laser melting produced chemically homogeneous glass spheres. Only highly (e.g. H2O) and moderately volatile components (Na, K) were partially lost. The composition of evaporated materials was determined by directly combining levitation and inductively coupled plasma mass spectrometry. It is shown that the evaporated material is composed of Na > K >> Si. Levitation of metal oxide-rich material in a mixture of H2 and Ar resulted in the exsolution of liquid metal. Levitation melting is a rapid technique or for the preparation of bulk rock powders for major, minor and trace element analysis. With exception of moderately volatile elements Na and K, bulk rock analyses can be performed with an uncertainty of ± 5% relative. The technique has great potential for the quantitative determination of evaporated materials from silicate melts. Reduction of oxides to metal is a means for the extraction and analysis of siderophile elements from silicates and can be used to better understand the origin of chondritic metal.

Thermophysical properties of liquid tin–bismuth alloys

Abstract: Tin–bismuth alloys are under intense consideration as favourable lead-free solders for consumer electronics and telecommunications. The electrical and thermal conductivity, viscosity, surface tension and density were studied in a wide temperature range above the liquidus. The scaling relations have been proposed. A comparison with data available in literature is given.

The calculation of Cs and Rb conductivities in the region of liquid–plasma transition

Abstract: The conductivity and thermal conductivity of Cs and Rb are calculated in the liquid phase and in the region between the plasma (gas) and the liquid states. The last area is located at the temperatures higher than the critical one, near the critical point. The Ziman formalism originated from the liquid metal theory was used for the calculations. The results of present calculations were compared with available experiments and calculations of other researchers. It was found that the liquid state formalism can be applied to expanded liquid Cs and Rb at densities higher than the critical one, but another type of models is necessary at lower densities.

The mystery of molten metal

Abstract: Recent advances in scientifi c understanding of high-temperature materials processing using novel experimental methodologies have shed light on the complex role of surface and interface phenomena. New in-situ studies on molten metal/solid ceramic interactions using a unique experimental complex at the Foundry Research Institute, Krakow, have revealed a number of unusual observations in materials processing at high temperatures. We present some such unusual observations and their explanation with reference to liquid metal processing of Al, Ni, and Ti, and their alloys in contact with oxide ceramics. In particular, we focus on the following aspects: primary oxidation of Al from residual water vapor or oxygen, capillary purification to remove surface oxide, substrate protection by CVD carbon, roughening due to spinel whisker formation, inclusions in castings due to mechanical detachment, fl oatation due to buoyancy forces, and segregation due to directional solidifi cation, modifi cation of the solid surface morphology by metal vapor ahead of the liquid, and the complication due to multi-component alloys melted in crucibles made from complex oxide-based ceramics. In the case of Ti, rapid reactions with oxides result in undesirable volumetric changes that create diffi culty in casting high-quality Ti parts, particularly by investment casting. Nanoscale (e.g., colloidal) coatings based on Y2O3 protect crucibles and hold ladles against such attack. Practical insights and recommendations for materials processing emerging from the fundamental studies on high- temperature interfacial phenomena have been described.

Systems and methods for plasma compression with recycling of projectiles

Abstract: Embodiments of systems and methods for compressing plasma are disclosed in which plasma can be compressed by impact of a projectile on a magnetized plasma in a liquid metal cavity. The projectile can melt in the liquid metal cavity, and liquid metal may be recycled to form new projectiles.