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Measurement and calculation of the viscosity of metals---a review of the current status and
developing trends
J Cheng, J Grbner, N Hort et al.
Abstract
Values of the viscosities of liquid metals are important in the prediction of
fluid flow in many metallurgical manufacturing processes. This paper
describes a number of methods used to measure the viscosity of liquid
metals, including capillary, oscillating vessel, rotational bob or crucible,
oscillating plate, draining vessel, levitation using the damping of surface
oscillations and acoustic methods. A number of models used to estimate
viscosity for elements, the temperature dependence of viscosity, and
viscosity of multicomponent systems are also given, including the Andrade
equation, Arrhenius equation, Hildebrands free volume theory, Chhabra
models, Moelwyn-Hughes model and thermodynamic models. The scatter
of data available in the literature are highlighted by comparing two reviews
of data for elements.
Keywords: viscosity, liquid metals, elements, alloys, models, estimation of
viscosity, measurement methods
(Some figures in this article are in colour only in the electronic version)
Positional
Adjuster
sensor wires
Gas Inlet
(O2 free)
known volume of liquid
Oscillation
Initiator
alumina seal
capillary tube Coupling
Torsion Wire
Supsension
3 zone furnace
cone to stop surface Temperature
tension effects Controlled
Jacket
catch pot (30C)
Mirror
water cooled sealed end piece
Window
where the values of Cl and C2 are easily evaluated using Diode Array
viscosity standard reference samples, but are constants equal
to Thermocouple
r 4 gh mV Water Cooled
C1 = , C2 = . (3) Section (Cold)
8V (l + nr) 8(l + nr)
In determining the viscosities of metallic liquids by the
capillary method, an especially fine and long-bore tube (in
general, r < 0.150.2 mm, l > 7080 mm) is needed so as to Suspension Rod
satisfy the condition of a low Reynolds number for ensuring
laminar flow. This in turn requires a furnace with a similarly Alumina Enclosure
long and uniform hot zone. Blockage of the capillary by
bubbles or oxide inclusions is a common problem, particularly Container
with aluminium alloys, and due to materials problems a
temperature limit of about 1200 C is often imposed, but metals Furnace
such bismuth have been successfully measured [1].
355
R F Brooks et al
1.2.1. The Roscoe analysis. Roscoe [4] describes the Figure 3. Reproduced from Beckwith and Newell [8], showing
derivation of the necessary formulae for determining viscosity region of interest 8 < 0 < 23, 68 < 0 < 200 to be within the large
from oscillatory spherical and cylindrical viscometers. The cup regime.
decay of the oscillations was determined from
these values for the NPL design correspond to the large cup
R3H 1 1R 3 4 R 1 regime.
I = (t) 2 1+ a0 +
2 4H 2 H p The corresponding operating equation due to Beckwith,
3 9R a2 63 45 R a4 in the form of Brockner et al [6], is
+ + (5)
8 4 H 2p 2 128 64 H 4p 4 H R 4 1 B Cq
A(p q) 2 + 3 = 2( o /) (9)
where 2I x x x
12 12 where
(1 + 2 ) + 1 1 + 2 1 R 16 R 3 9R
a0 = (1 ) (1 + ) A=4+ , B =6+ , C= + ,
2 2 H H 2 H
3 3 1 to 1
1
= 1 2 3 (6) = , p = 1 2 + (1 + 2 ) 2 2 ,
2 8 16 t
12 12 1 1
1 + 2 + 1 1 + 2 1 q= , x = R(2/(t)) 2
a2 = + 2p
2 2
where to is the oscillation period and 2o is the logarithmic
1 2 1 decrement for the empty cup. The other quantities are as
=1+ + 3 (7)
2 8 16 defined in the previous section.
2 12 3 5
a4 = a2 /(1 + ) = 1 + 2 3 (8) 1.2.3. Numerical comparisons. Comparing the treatments
2 8 16
with a typical set of NPL measurement data for iron, the
and corrected Roscoe equation (2.5) gives 6.047 mPa, while the
1
p = (/t) 2 R. corresponding value calculated using the BeckwithNewell
analysis (3.2) yields 6.044 mPa. For the aluminium data, the
In (11), R is the cylinder radius, H the height of the liquid viscosity results for the Roscoe and BeckwithNewell analyses
within it, I the moment of inertia of the suspension, 2 are 0.949 mPa s and 0.954 mPa s, respectively. The difference
the logarithmic decrement between consecutive swings, the between the results for aluminium is about 0.5% and that for
fluid density, the viscosity and t is the period of oscillation. steel very much less.
In his review of the equations Ferriss [9] found that (12)
was printed incorrectly in the original paper, and should be 1.2.4. Possible errors. Comparison of the oscillating
read as (3/2), as given above. viscometer with the capillary viscometer reveals some
differences. Iida and Guthrie [1] suggest the end effect is
1.2.2. The Beckwith, Kestin and Newell analysis. The inadequately weighted in the Roscoe treatment and should
analysis due to Kestin and Newell [5] and Beckwith and also include the effect of the liquid meniscus on the height
Newell [8] identifies the small, intermediate and large cup of liquid, suggesting that a correction factor, , is introduced
regimes according to the magnitude of certain dimensionless into the (uncorrected) formula of 1 0.04. Various studies
parameters (figure 3). Ferriss et al [9] have shown that [1, 1114] have suggested that wetting of the crucible may also
356
The measurement of viscosity of alloys
alumina cap
computer
thermocouple
oscillating plate
357
R F Brooks et al
displacement
Viscometer head transducer coil
core holder
load
articulated load cell
Mo spindle
pully
x-y stage
reference rod
sample (for expansion)
Mo bob
furnace spiked disk
Mo crucible sample
rotary disk
furnace
thermocouple
i.e. a bob and a crucible. The viscosity is determined Figure 7. Spiked parallel plate creep/rotational viscometer.
from measurements of the torque generated on the rotor arm
of the rotating cylinder. When rotating the cylinder at a
range, 107 to 104 Pa s, and a rotating plate method for the lower
constant speed the viscosity can be obtained from the following
range. The plate acts in the same way as the rotating cylinder,
equation:
with a large surface area to obtain the necessary sensitivity. It
1 1 M is claimed that because the principles and mechanism of this
= 2 (13)
r12 r0 8 4 nh viscometer are simple, the absolute values of sample viscosity
where M is the torque, n is the number of revolutions per can be determined, at least to the right order, without any
second, r1 is the radius of the bob, r0 is the radius of the calibration using standard reference samples. There are no
crucible, and h is the height of the bob. The theory is applicable reports of it being used on liquid metals.
to infinitely long cylinders and it is normal to calibrate the
system with reference materials using the equation 1.6. Industrial viscometers
= G = S/n (14) Several simple viscometers have been developed for on
where S is the scale deflection and G is the apparatus constant. plant determination of slag viscosities and quality assurance
This is the most common method for the measurement exercises, but these have not been used for liquid metals.
of slag viscosity and for several practical reasons it is more Examples are the Herty viscometer [29] where the viscosity
customary to rotate the bob rather than the crucible. A typical is determined by the length of the slag ribbon formed, and
rotating bob apparatus is shown in figure 6. Probably the most the Krabiell immersion viscometer [30, 31]. In recent years
important reason is that the rotating bob viscometer is based the inclined plane method has been investigated in more
upon readily available and cheap commercial instruments. It detail [32]. In this method a molten slag is poured from a
is also easier to centre the bob, but the viscosity range is less crucible onto an inclined steel plate plane with a V section.
than for a rotating crucible instrument. It is critical that the bob The viscosity can be related to the length of the slag ribbon
rotates axisimetrically and concentrically within the sample. obtained. Mills et al [32] claim that measurement uncertainties
Any instability due to rotation speed or alignment will increase of 15%, for slags with viscosities in the range of 0.1 to
the apparent viscosity. Nakashima et al [26] show a modern 1 Pa s, are possible. The oscillating plate method has also
example of a rotating crucible method. been proposed as an in situ measurement.
In order to obtain the necessary sensitivity to measure
the low viscosity of liquid metals the clearance between the 1.7. Draining vessel method
stationary and rotating parts has to be made very small, and
it is difficult to maintain the system coaxially. In spite of the It is common for comparative measurements of viscosity to be
experimental difficulties the rotating bob technique has been made for oils and slurries in industrial applications by use of
used to measure the viscosity of aluminium and its alloys [27]. a flow cup, where the time taken for a volume of sample to
An adaptation of this method has been developed as part flow through a small orifice in the bottom of a cup is measured
of a spiked parallel plate creep/rotational viscometer [28], and viscosity is derived from look-up tables. Roach et al [33]
shown in figure 7. This elegant design to measure a wide range have derived equations to adapt this method for liquid metals,
of viscosities from about 1012 to 101 Pa s has been successfully and to provide values of viscosity, surface tension and density.
demonstrated with various glasses to a temperature of 1200 C. The apparatus is shown in figure 8. The values for aluminium
The instrument combines an indentation method for the highest are lower than usually quoted, but the method is robust and
viscosities, a creep parallel plate method for the intermediate experiments simple to perform.
358
The measurement of viscosity of alloys
600
thermocouple
PdCuSi shape oscillations at 950 C
590
580
induction coil
amplitude [a.u.]
h 570
560
550
Q r0 stopper
540
0 1 2 3 4 5 6 7 8
time [s]
Figure 8. Diagram of a draining vessel viscometer. material has a low viscosity and unphysically high results
for the viscosity were obtained, indicating turbulent flows in
1.8. Oscillating (levitated) drop method the sample. During the MSL-1 Spacelab mission STS-83,
the same experiment was carried out on the highly viscous
The oscillating drop method is widely used for surface tension eutectic system Pd78Cu6Si16 [38]. The values agree well with
measurements of liquid, levitated samples. It is based on the one set of previously published data for the viscosity of this
fact that the frequencies of the surface oscillations of a liquid alloy near the melting point, although there is debate as to the
drop are related to the surface tension by Rayleighs formula true viscosity of this system. More recently Wunderlecht et al
[34]; for earthbound levitation, his formula must be corrected [39] have carried out measurements on parabolic and sounding
as proposed by Cummings and Blackburn [35]. For a viscous rocket flights, on the nickel based superalloy CMSX-4 which
drop, these oscillations are damped due to the viscosity of the show reasonable agreement with terrestrial measurements of
liquid. Therefore, it is, in principle, also possible to determine the same alloy using an oscillating cylinder method.
the viscosity from the damping. The damping constant is
given by
1.9. Damping of an acoustic wave
20 R
= (15) The viscosity of a liquid can be measured by measuring the
3 m
where R and m are radius and mass of the droplet, respectively, damping of an acoustic wave. There is one example for the
and is the viscosity. In order to apply the above formula, the measurement of aluminium [40] and some alloys, using hole
following conditions must be satisfied: theory to interpret the results.
359
R F Brooks et al
Table 1. Data for the viscosity of relevant elements drawn from two compendia [41, 42].
Melting point (Tm) o E (Tm) [2]
Element Tm ( C) (mPa s) (mPa s) (kJ mol1) (kg m3)
3. Models for viscosity of metals parameters. Chhabra investigated three common models:
Arrhenius, Andrade and the Hildebrand fluidity equation, and
The following section presents some of the models that compared them against experimental data.
are used to describe the viscosity of the elements and
multicomponent systems. The list is not comprehensive
3.1.3. Arrhenius equation. The Arrhenius equation is the
and we have not included molecular models or relationships
one most frequently used to represent data on viscosity:
between liquid diffusion coefficients and viscosity such as the
StokesEinstein equation. = A exp(E/RT ). (18)
T is the temperature in K, A is the pre-exponential factor, R
3.1. Elements
is the gas constant and E is the activation energy for viscous
3.1.1. Andrade equation for viscosity at melting point. This flow.
model [43] is based upon the supposition that the characteristic Chhabra et al [44] derive values for A and E from various
vibration frequencies in the liquid (L ) and solid (S ) near the experimental data for Ag, Al, Au, Bi, Ca, Cd, Co, Ca, Cu, Fe,
melting point are equal using the fact that the specific heats of Ga, Ge, Hg, In, K, Li, Mg, Na, Ni, Pb, Pu, Rb, Sb, Sn, Tl
liquid and solid metals at their melting point are similar. and Zn.
(Tm ) = CA {Tm A}1/2 /V 2/3 . (17)
Andrade showed that CA is approximately a constant for 3.1.4. Andrade treatment. The equation by Andrade [43]
pure metal melts and estimated a value of 1.65 107 described above underestimates the temperature dependence
(J K1 mol1/3 )1/2 with A = atomic weight and V = molar of viscosity, and so Andrade suggested that the viscosity was
volume at Tm. lowered by the loss of local molecular orientational order but
Battezati and Greer [42] have tested Andrades equation there is a discussion whether this is a tenable argument [41].
and note several exceptions to the predicted value of CA due Andrade gave an equation in the form
to: the reliability of available data for some elements; the (T ) = C1 / 1/3 exp(C2 /T ) (19)
formation of associates in elements such as selenium; and the
anomalous behaviour of semiconductors in the solid and in where C1 and C2 are constants and is the specific volume.
the liquid. This is similar to the Arrhenius equation [42, 44].
Hirai [46] modified the Andrade equation based upon
3.1.2. Temperature dependence of viscosity of the elements. characteristic frequency of vibration to give
There are a large number of equations that have been derived (Tm ) = 1.7 107 2/3 Tm 1/2 M 1/6 (Pa s) (20)
to describe the viscosity as a function of temperature for
pure liquids. (See Chhabra and Seth [44] and Beyer and where is the density, M is the atomic weight. Using
Ring [45].) These frequently involve two or three adjustable a compendium of data [47] he derived the following
360
The measurement of viscosity of alloys
relationships for the viscosity of the elements: at two temperatures there was a maximum difference of 8%
= A exp(E/RT ) (21) between the predicted and measured values.
where 3.2.3. Thermodynamic models [4648]. There have been
A = {1.7 107 2/3 Tm 1/2 M 1/6 }/A exp(E/RTm ) attempts to model viscosity using thermodynamic concepts
and [48, 55, 56]. Kucharski [55, 56] developed two models: one
based upon rate theory to describe multicomponent mixtures
E = 2.65 Tm 1.27 .
where all the parameters have physical meaning and another
Although the expressions describe the viscosity of the elements model predicting multicomponent mixtures from knowledge
well and have formed the basis of the unary data for at least of thermodynamic properties, densities and viscosities for the
one model [48] extension of these equations to alloys has not limiting binaries. She tested this for a AgCuAu system. Du
met with success. Sichen et al [48] used an absolute reaction rate theory and were
able to reproduce the viscosity of some binary compositions
3.1.5. Hildebrands free volume theory. The principle of this well.
model [49] is that fluid flow is governed by the extent of the
free space available: Acknowledgments
1/ = = B{(V V0 )/V0 }. (22)
This work formed part of the Measurements for
V is the atomic volume, V0 is the intrinsic volume where flow Processability Programme of the UKs Department of Trade
is stopped, B is a characteristic constant. Both B and V0 are and Industry.
considered constants independent of temperature.
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