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Office of Scientific and Technical Information
Chameleon foreCAST
E-Print Network (OSTI)
Dark energy models, such as the chameleon, where the acceleration of the expansion of the universe results from the dynamics of a scalar field coupled to matter, suffer from the potential existence of a fifth force. Three known mechanisms have been proposed to restore General Relativity in the solar system and the laboratory, which are the symmetron/Damour-Polyakov effect, the Vainshtein property and the chameleon screening. Here, we propose to probe the existence of chameleons in the laboratory, considering their particle physics consequences. We envisage the resonant and non-resonant production of chameleons in the sun and their back-conversion into X-ray photons in a solar helioscope pipe such as the one used by CAST. A detection of these X-rays would indicate the existence of chameleons. We focus on a template model for the solar magnetic field: a constant magnetic field in a narrow shell surrounding the tachocline. The X-ray photons in a helioscope pipe obtained from back-conversion of the chameleons created inside the sun have a spectrum which is peaked in the sub-keV region, just below the actual sensitivity range of the present axion helioscopes. Nevertheless they are detectable by present day magnetic helioscopes like CAST and Sumico, which were built originally for solar axions. We also propose a chameleon-through-a-wall experiment whereby X-ray photons from a synchroton radiation source could be converted into chameleons inside a dipole magnet, then pass a wall which is opaque to X-rays before being back-converted into X-ray photons in a second magnet downstream. We show that this could provide a direct signature for the existence of chameleon particles.
Philippe Brax; Axel Lindner; Konstantin Zioutas
Energy.gov (U.S. Department of Energy (DOE)) Indexed Site
36DOWCHEMICALCOMPANYWaiverofDomesticandFore.pdf WA1993036DOWCHEMICALCOMPANYWaiverofDomesticandFore.pdf WA1993036DOWCHEMICALCOMPANYWaiverofDomesticandFor...
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Casting Processes
Science Conference Proceedings (OSTI)
Table 1 General characteristics of casting processes...casting processes Characteristic Casting process Green sand Resin-bonded sand Plaster Lost foam Investment Permanent mold Die Part Material (casting) All All Zn to Cu Al to cast iron All Zn to cast iron Zn to Cu Porosity and voids (a) C-E D-E D-E C-E E B-C A-C Shape (b) All All All All All Not T3, 5,...
FORECASTING A CORONAL MASS EJECTION'S ALTERED TRAJECTORY: ForeCAT
To predict whether a coronal mass ejection (CME) will impact Earth, the effects of the background on the CME's trajectory must be taken into account. We develop a model, ForeCAT (Forecasting a CME's Altered Trajectory), of CME deflection due to magnetic forces. ForeCAT includes CME expansion, a three-part propagation model, and the effects of drag on the CME's deflection. Given the background solar wind conditions, the launch site of the CME, and the properties of the CME (mass, final propagation speed, initial radius, and initial magnetic strength), ForeCAT predicts the deflection of the CME. Two different magnetic backgrounds are considered: a scaled background based on type II radio burst profiles and a potential field source surface (PFSS) background. For a scaled background where the CME is launched from an active region located between a coronal hole and streamer region, the strong magnetic gradients cause a deflection of 8. Degree-Sign 1 in latitude and 26. Degree-Sign 4 in longitude for a 10{sup 15} g CME propagating out to 1 AU. Using the PFSS background, which captures the variation of the streamer belt (SB) position with height, leads to a deflection of 1. Degree-Sign 6 in latitude and 4. Degree-Sign 1 in longitude for the control case. Varying the CME's input parameters within observed ranges leads to the majority of CMEs reaching the SB within the first few solar radii. For these specific backgrounds, the SB acts like a potential well that forces the CME into an equilibrium angular position.
Kay, C.; Opher, M. [Astronomy Department, Boston University, Boston, MA 02215 (United States); Evans, R. M., E-mail: email@example.com [NASA Goddard Space Flight Center, Space Weather Lab, Greenbelt, MD 20771 (United States)
CAST SHOP TECHNOLOGY: V: Cast House Safety
TMS Logo. 1997 TMS Annual Meeting: Wednesday Session. CAST SHOP TECHNOLOGY: Session V: Cast House Safety. Sponsored by: LMD Aluminum�...
Investment Casting
...In investment casting, also called the "lost wax" process, a ceramic slurry is applied around a pattern, usually made of wax, and hardened to make a mold. The pattern is removed, usually by heat, and molten alloy is poured into the space formerly
Casting methods
DOE Patents (OSTI)
A casting device includes a covered crucible having a top opening and a bottom orifice, a lid covering the top opening, a stopper rod sealing the bottom orifice, and a reusable mold having at least one chamber, a top end of the chamber being open to and positioned below the bottom orifice and a vacuum tap into the chamber being below the top end of the chamber. A casting method includes charging a crucible with a solid material and covering the crucible, heating the crucible, melting the material, evacuating a chamber of a mold to less than 1 atm absolute through a vacuum tap into the chamber, draining the melted material into the evacuated chamber, solidifying the material in the chamber, and removing the solidified material from the chamber without damaging the chamber.
Marsden, Kenneth C.; Meyer, Mitchell K.; Grover, Blair K.; Fielding, Randall S.; Wolfensberger, Billy W.
A DEVS fire jumps model and associated simulations using ForeFire
This paper describes a simple physical model of the phenomenon of fire jumps. The model behaviour is developed using DEVS Formalism and simulated in Discrete Event fashion. The aim of this work is to be able to simulate this phenomenon within the ForeFire ... Keywords: discrete events simulation, fire spread, firebrand model, fires jumps, forest
Bahaa Nader; Jean Baptiste Filippi; Paul Antoine Bisgambiglia
STEM-ing the Tide | Department of Energy
STEM-ing the Tide STEM-ing the Tide STEM-ing the Tide September 29, 2010 - 4:29pm Addthis Ali Zaidi Special Assistant to the Secretary of Energy Yesterday, the MacArthur Foundation rolled out its latest class of "geniuses" - 23 Americans who stand out because of their creativity and enterprise. Each recipient of the honor (and the $500,000 prize) has made an extraordinary contribution. One of those recipients is Amir Abo-Shaeer, an engineer in the aerospace and telecommunications industries who decided 10 years ago to go back to high school - this time as a teacher. At his alma mater, Dos Pueblos High School (in Santa Barbara, California), Amir created "a school within a school" built around a hands-on curriculum that helps students learn by connecting the ideas of physics, engineering and mathematics through
Metal Casting Methods
Table 7 General characteristics of casting processes...Characteristic Casting process Green sand Resin-bonded sand Plaster Lost foam Investment Permanent mold Die Part Material (casting) All All Zn to Cu Al to cast iron All Zn to cast iron Zn to Cu Porosity and voids (a) C�??E D�??E D�??E C�??E E B�??C A�??C Shape (b) See Fig. 1 for shapes All All...
Cast Irons - Programmaster.org
Oct 20, 2011 ... Processing, Microstructure and Properties of Cast Irons and Cast and Forged Specialty Steels: Cast Irons Sponsored by: MS&T Organization
Personnel Change Notification ImagIng: GRSF/T
Personnel Change Notification OGS Form 3 ImagIng: GRSF/T Admit Year/Term: GS Web Front Desk: Office., reviewers, coordinators and chairs) Update: View all AIM Graduate Studies pages and enter decisions on GS02: Search for and view applicants; edit emails Connect: Add, search for and communicate with prospects
Hart, Gus
S>A process is described for preparing a magnesium oxide slip casting slurry which when used in conjunction with standard casting techniques results in a very strong "green" slip casting and a fired piece of very close dimensional tolerance. The process involves aging an aqueous magnestum oxide slurry, having a basic pH value, until it attains a specified critical viscosity at which time a deflocculating agent is added without upsetting the basic pH value.
Allison, A.G.
AUTOMOTIVE ALLOYS: III: Castings
Coal fly ash, an industrial waste by-product, is produced during combustion of ... DIE CASTING FOR AUTOMOTIVE APPLICATIONS--A Status Report: Hubert�...
cast shop technology i
Guy Leblanc, and Vincent J. Newberry. Laboratory Investigations About the Influence of Starting Conditions on Butt Curl and Swell of DC Cast Sheet Ingots [
Casting & Solidification 1
Jun 4, 2012 ... Study on Electromagnet-Air Knife DC Casting Process of Large-Size AA .... High shear melt conditioning of aluminum alloy melts disperses�...
Copper Casting Alloys
Table 8 Compositions, uses, and characteristics of copper alloy castings...operating at moderate-to-high speeds, as in electric motors and appliances. Alloy C93200 is
Investment Casting - TMS
Apr 27, 2007 ... PDF PRIMER: Investment Casting The basic process for producing superalloy components of a complex shape, 0, 1218, Lynette Karabin�...
Processing, Microstructure and Properties of Cast Irons and Cast ...
... Process Design of the Ductile Cast Iron Cylinder Head for Marine Diesel Engine ... Heavy Section Ductile Iron Castings for Use in Wind Turbine Generators.
Casting Flow Chart
Figure: ...Fig. 1 Simplified flow diagram of the basic operations for producing a steel casting. Similar diagrams can be applied to other ferrous and nonferrous alloys produced by sand
Grain Refinement and Castings
Mar 13, 2012 ... Program Organizers: Trond Furu, Hydro ... Full scale DC casting trials of 6xxx alloy were performed. ... Small polyhedral silicon particles and globular aluminum grains were formed in the region near the probe (zone one).
A coated mold for casting plutonium comprises a mold base portion of a material which remains solid and stable at temperatures as high as the pouring temperature of the metal to be cast and having a thin coating of the order of 0.005 inch thick on the interior thereof. The coating is composed of finely divided calcium fluoride having a particle size of about 149 microns. (AEC)
Anderson, J.W.; Miley, F.; Pritchard, W.C.
Method of casting aerogels
The invention describes a method for making monolithic castings of transparent silica aerogel with densities in the range from 0.001 g/cm[sup 3] to 0.6 g/cm[sup 3]. Various shapes of aerogels are cast in flexible polymer molds which facilitate removal and eliminate irregular surfaces. Mold dimensions are preselected to account for shrinkage of aerogel which occurs during the drying step of supercritical extraction of solvent. 2 figures.
Poco, J.F.
The invention describes a method for making monolithic castings of transparent silica aerogel with densities in the range from 0.001 g/cm.sup.3 to 0.6 g/cm.sup.3. Various shapes of aerogels are cast in flexible polymer molds which facilitate removal and eliminate irregular surfaces. Mold dimensions are preselected to account for shrinkage of alcogel which occurs during the drying step of supercritical extraction of solvent.
Poco, John F. (Livermore, CA)
Salvaged castings and methods of salvaging castings with defective cast cooling bumps
SciTech Connect
Castings for gas turbine parts exposed on one side to a high-temperature fluid medium have cast-in bumps on an opposite cooling surface side to enhance heat transfer. Areas on the cooling surface having defectively cast bumps, i.e., missing or partially formed bumps during casting, are coated with a braze alloy and cooling enhancement material to salvage the part.
Johnson, Robert Alan (Simpsonville, SC); Schaeffer, Jon Conrad (Greenville, SC); Lee, Ching-Pang (Cincinnati, OH); Abuaf, Nesim (Lincoln City, OR); Hasz, Wayne Charles (Pownal, VT)
"Dark Web: Exploring and Min-ing the Dark Side of the Web"
Title: "Dark Web: Exploring and Min- ing the Dark Side of the Web" Speaker: Director, Prof will review the emerging research in Terrorism Informatics based on a web mining perspective. Recent progress in the internationally re- nowned Dark Web project will be reviewed, including: deep/dark web spider- ing (web sites
Michelsen, Claus
13:00 Begrung und Symposiumserffnung Prof. Dr.-Ing. Gerd Holbach
Windenergie-Gewinnung Dipl.-Ing. Jörgen Thiele Stiftung Offshore-Windenergie, Varel 14:45 Evolution der Meyer Werft GmbH, Papenburg 14:00 Energiewende als Chance und Heraus- forderung am Beispiel der Offshore challenges for ships and offshore structures (Englisch) Dr.-Ing. Bas Buchner, Maritime Research Institute
Berlin,Technische Universität
Direct Casting Methods
Table 10 Alternative sheet, strip, and slab casting techniques...Armco Single roll Allegheny-Ludlum Single roll Argonne National Labs Electromagnetic levitation United Technologies Single roll LTV Drum in drum Japan Nippon Steel Twin roll Kawasaki Steel Twin roll Nippon Kokan Twin roll Nippon Metals Twin roll Kobe Twin roll Nippon Yakin Twin roll France IRSID Twin...
Computer cast blast modelling
Cast blasting can be designed to utilize explosive energy effectively and economically for coal mining operations to remove overburden material. The more overburden removed by explosives, the less blasted material there is left to be transported with mechanical equipment, such as draglines and trucks. In order to optimize the percentage of rock that is cast, a higher powder factor than normal is required plus an initiation technique designed to produce a much greater degree of horizontal muck movement. This paper compares two blast models known as DMC (Distinct Motion Code) and SABREX (Scientific Approach to Breaking Rock with Explosives). DMC, applies discrete spherical elements interacted with the flow of explosive gases and the explicit time integration to track particle motion resulting from a blast. The input to this model includes multi-layer rock properties, and both loading geometry and explosives equation-of-state parameters. It enables the user to have a wide range of control over drill pattern and explosive loading design parameters. SABREX assumes that heave process is controlled by the explosive gases which determines the velocity and time of initial movement of blocks within the burden, and then tracks the motion of the blocks until they come to a rest. In order to reduce computing time, the in-flight collisions of blocks are not considered and the motion of the first row is made to limit the motion of subsequent rows. Although modelling a blast is a complex task, the DMC can perform a blast simulation in 0.5 hours on the SUN SPARCstation 10--41 while the new SABREX 3.5 produces results of a cast blast in ten seconds on a 486-PC computer. Predicted percentage of cast and face velocities from both computer codes compare well with the measured results from a full scale cast blast.
Chung, S. [ICI Explosives Canada, North York, ON (Canada); McGill, M. [ICI Explosives USA, Dallas, TX (United States); Preece, D.S. [Sandia National Labs., Albuquerque, NM (United States)
Melting and casting of FeAl-based cast alloy
The FeAl-based intermetallic alloys are of great interest because of their low density, low raw material cost, and excellent resistance to high-temperature oxidation, sulfidation, carburization, and molten salts. The applications based on these unique properties of FeAl require methods to melt and cast these alloys into complex-shaped castings and centrifugal cast tubes. This paper addresses the melting-related issues and the effect of chemistry on the microstructure and hardness of castings. It is concluded that the use of the Exo-Melt{trademark} process for melting and the proper selection of the aluminum melt stock can result in porosity-free castings. The FeAl alloys can be melted and cast from the virgin and revert stock. A large variation in carbon content of the alloys is possible before the precipitation of graphite flakes occurs. Titanium is a very potent addition to refine the grain size of castings. A range of complex sand castings and two different sizes of centrifugal cast tubes of the alloy have already been cast.
Sikka, V.K. [Oak Ridge National Lab., TN (United States); Wilkening, D. [Columbia Falls Aluminum Co., Columbia Falls, MT (United States); Liebetrau, J.; Mackey, B. [AFFCO, L.L.C., Anaconda, MT (United States)
Extrusion cast explosive
Disclosed is an improved, multiphase, high performance, high energy, extrusion cast explosive compositions, comprising, a crystalline explosive material; an energetic liquid plasticizer; a urethane prepolymer, comprising a blend of polyvinyl formal, and polycaprolactone; a polyfunctional isocyanate; and a catalyst. These new explosive compositions exhibit higher explosive content, a smooth detonation front, excellent stability over long periods of storage, and lower sensitivity to mechanical stimulants. 1 fig.
Scribner, K.J.
Improved, multiphase, high performance, high energy, extrusion cast explosive compositions, comprising, a crystalline explosive material; an energetic liquid plasticizer; a urethane prepolymer, comprising a blend of polyvinyl formal, and polycaprolactone; a polyfunctional isocyanate; and a catalyst are disclosed. These new explosive compositions exhibit higher explosive content, a smooth detonation front, excellent stability over long periods of storage, and lower sensitivity to mechanical stimulants. 1 fig.
History of Metal Casting
Table 3 Chronological list of developments in the use of materials...iron China 224 B.C. Colossus of Rhodes destroyed Greece 200�??300 A.D. Use of mercury in gilding (amalgam gilding) Roman world 1200�??1450 A.D. Introduction of cast iron (exact date and place unknown) Europe Circa 1122 A.D. Theophilus's On Divers italic> the first
Cast dielectric composite linear accelerator
A linear accelerator having cast dielectric composite layers integrally formed with conductor electrodes in a solventless fabrication process, with the cast dielectric composite preferably having a nanoparticle filler in an organic polymer such as a thermosetting resin. By incorporating this cast dielectric composite the dielectric constant of critical insulating layers of the transmission lines of the accelerator are increased while simultaneously maintaining high dielectric strengths for the accelerator.
Sanders, David M. (Livermore, CA); Sampayan, Stephen (Manteca, CA); Slenes, Kirk (Albuquerque, NM); Stoller, H. M. (Albuquerque, NM)
Casting and Solidification of Metals
Casting methoding engineers will be targeted, although management at any level will find the course intelligible and valuable to ... ENERGY MANAGEMENT.
Advances in Metal Casting Technologies
Mar 31, 2013... process controls), environmental controls, sustainability, health and safety. ... A Study on Applicastion of the Squeeze Casting Process to the�...
'Spin Casting' And 'Cold Deformation'
Numerical Modeling of Centrifugally Cast HSS Rolls � Numerical Simulation of Electro-magnetic Turbulent Inhibitor Technology in a Tundish � Optimizing the�...
Cast Shop for Aluminum Production
Organizer(s), Trond Furu, Hydro ... Review at Several US Aluminum Die Cast Manufacturers Using Unique, Non-Wetting, Micro-Porous Refractory Products.
"Cook"ing at Y-12 for 70 years | Y-12 National Security Complex
NLE Websites -- All DOE Office Websites (Extended Search)
"Cook"ing at Y-12 ... "Cook"ing at Y-12 ... "Cook"ing at Y-12 for 70 years Posted: December 5, 2013 - 4:48pm At a Nov. 14 visit to Y-12, National Nuclear Security Administration's Deputy Administrator for Defense Don Cook shared his outlook on the future and his thanks to employees for continuing their 70-year tradition of making America safer. "There are three things to remember," Cook told a meeting of NNSA Production Office and Y-12 employees. "We have an enduring mission. Y-12 plays a key role in it. And a nuclear deterrent remains the ultimate insurance policy for America." Cook also shared his thanks for preparing for the potential furlough in October because of the government shutdown and lack of appropriations. During what was the longest government shutdown to date, Cook said Y-12
"Freckles" in Cast and Wrought Products
alloy 718 investment casting, one in an alloy 706 forging. ... The freckle that was found in a large, structural, investment casting is illustrated in Figure 1.
Ohno continuous casting
Production of net-shape products directly from the liquid is an attractive manufacturing route for alloys that are difficult to process or that cannot be rolled, drawn, or extruded. Developed at the Chiba Institute of Technology in Japan, the Ohno Continuous Casting (OCC) approach not only provides significant cost savings, but also has the potential to create new products. OCC process equipment includes a melting furnace, crucible, mold level-control block, cooling device, and pinch rolls. OCC is currently used to produce copper rods and wires for audio and video cables, and aluminum alloy welding rods for hard-surfacing applications. For example, Mitsui Engineering and Ship Building Co. has used OCC to produce copper tubing products with internal fins and partitions for applications such as heat exchanger tubes and induction coils.
Soda, H.; McLean, A. [Univ. of Toronto, Ontario (Canada); Motoyasu, G.; Ohno, A. [Chiba Institute of Technology (Japan)
TRANSPORTATION SYSTEMS are the build-ing blocks of modern society. Efficient and
TRANSPORTATION SYSTEMS are the build- ing blocks of modern society. Efficient and safe movement. How- ever, transportation systems by their very nature also affect the environment through operations, construction, and maintenance of transportation facilities, and through the travel behaviors they encourage
Wang, Yuhang
Water is used for many purposes, includ-ing growing crops, producing copper,
WATER USES Water is used for many purposes, includ- ing growing crops, producing copper, generating electricity, watering lawns, keeping clean, drinking and recreation. Bal- ancing the water budget comes down of the water budget. Reducing demand involves re- ducing how much water each person uses, lim- iting the number
Strip casting with fluxing agent applied to casting roll
A strip caster (10) for producing a continuous strip (24) includes a tundish (12) for containing a melt (14), a pair of horizontally disposed water cooled casting rolls (22) and devices (29) for electrostatically coating the outer peripheral chill surfaces (44) of the casting rolls with a powder flux material (56). The casting rolls are juxtaposed relative to one another for forming a pouting basin (18) for receiving the melt through a teeming tube (16) thereby establishing a meniscus (20) between the rolls for forming the strip. The melt is protected from the outside air by a non-oxidizing gas passed through a supply line (28) to a sealing chamber (26). A preferred flux is boron oxide having a melting point of about 550.degree. C. The flux coating enhances wetting of the steel melt to the casting roll and dissolves any metal oxide formed on the roll.
Williams, Robert S. (Fairfield, OH); O' Malley, Ronald J. (Miamisburg, OH); Sussman, Richard C. (West Chester, OH)
A strip caster for producing a continuous strip includes a tundish for containing a melt, a pair of horizontally disposed water cooled casting rolls and devices for electrostatically coating the outer peripheral chill surfaces of the casting rolls with a powder flux material. The casting rolls are juxtaposed relative to one another for forming a pouting basin for receiving the melt through a teeming tube thereby establishing a meniscus between the rolls for forming the strip. The melt is protected from the outside air by a non-oxidizing gas passed through a supply line to a sealing chamber. A preferred flux is boron oxide having a melting point of about 550 C. The flux coating enhances wetting of the steel melt to the casting roll and dissolves any metal oxide formed on the roll. 3 figs.
Williams, R.S.; O`Malley, R.J.; Sussman, R.C.
ing system
Oct 29, 2002 ... GAs are search algorithms based on the mechanics of natural selection and natural genetics. They combine the concept of survival of the.
Following weeks of purging and organiz-ing, phase one of the School's reloca-
in August. The depart- ments of Consumer Science and Human Development and Family Studies, as well as UW from top: Gloria McCord, Human Ecology financial specialist, casts a spell at the punch-bowl cauldron
Sheridan, Jennifer
Microstructural Characterization of Cast 718
structural hardware. The mechanical properties of cast 718 have greatly .... hrs, Furnace Cool lOO'F/hr to 115O'F/8 hrs, Air Cool. (in a suitable protective.
Cast Alloy Compositions
Table 2 Nominal Compositions of Cast Nickel-Base Superalloys...5.0 8.0 2.0 8.0 6.0 �?� �?� �?� 5.0 1.5 0.1 �?�. �?� �?� MC-NG �?� 4.0 1.0 5.0 5.0 4.0 4.0 �?� 6.0 0.5 0.1 �?� �?� �?� MC-102 �?� 20.0 6.0 2.5 0.6 �?� 6.0 �?� �?� �?� 0.04 �?� �?� 0.25 Si, 0.30 Mn MK-4 9.4�??9.6 6.4�??6.6 0.6 6.4�??6.6 7.2�??7.5 3.0�??3.2 5.60 0.6�??0.9 0.15�??0.2 0.02�??0.03 50�??60 ppm MX-4 16.5 2 2 6 8.25 5.95 3 5.55 ---- 0.15 0.03...
WEB RESOURCE: Magnesium Cast Products Flow Chart - TMS
Aug 18, 2007 ... The following flow charts attempt to list important cast magnesium products being made as die castings, sand and permanent mold castings�...
Blasting casting to raise productivity
Normally, surface mines employ draglines or truck and shovel systems to remove overburden. Blasting merely fragments and displaces the overburden enough to allow for easy digging. But during the past two decades, the effect of inflation and increased labor costs have encouraged unconventional methods of overburden removal. All of us are aware of the tremendous inflationary effects on costs of equipment, fuel, labor, interest, insurance, environmental compliance, etc. This has allowed the authors to take a new look at the use of explosives as an effective alternate method of overburden removal. This technique is known by several names, but basically blast casting or just casting best describes it. Other terms in vogue are explosive casting, controlled trajectory blasting, trajectory control blasting, and whatever terminology comes to mind.
Pilshaw, S.R.
Energy Consumption of Die Casting Operations
Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption [1]. The obvious major energy requirements are for melting and holding molten alloy in preparation for casting. The proper selection and maintenance of melting and holding equipment are clearly important factors in minimizing energy consumption in die-casting operations [2]. In addition to energy consumption, furnace selection also influences metal loss due to oxidation, metal quality, and maintenance requirements. Other important factors influencing energy consumption in a die-casting facility include geographic location, alloy(s) cast, starting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting machine, related equipment (robots, trim presses), and downstream processing (machining, plating, assembly, etc.). Each of these factors also may influence the casting quality and productivity of a die-casting enterprise. In a die-casting enterprise, decisions regarding these issues are made frequently and are based on a large number of factors. Therefore, it is not surprising that energy consumption can vary significantly from one die-casting enterprise to the next, and within a single enterprise as function of time.
Jerald Brevick; clark Mount-Campbell; Carroll Mobley
MS&T '04 Volume 2: Continuous Casting Fundamentals, Engineered
Continuous Casting Fundamentals I � Initial Solidification and Interfacial .... Continuous Casting Fundamentals II � Mold Fluid Flow and Water Spray Cooling.
Characterization of Vacuum Die Cast Inconel 718 and Derivatives ...
Development and evaluation of investment cast Inconel 718 as a processing ... investment cast structural applications that several technical issues were�...
Fisher4Cast Users' Manual
This is the Users' Manual for the Fisher Matrix software Fisher4Cast and covers installation, GUI help, command line basics, code flow and data structure, as well as cosmological applications and extensions. Finally we discuss the extensive tests performed on the software.
Bruce A. Bassett; Yabebal Fantaye; Ren�e Hlozek; Jacques Kotze
Advanced Lost Foam Casting Technology
This report describes the research done under the six tasks to improve the process and make it more functional in an industrial environment. Task 1: Pattern Pyrolysis Products and Pattern Properties Task 2: Coating Quality Control Task 3: Fill and Solidification Code Task 4: Alternate Pattern Materials Task 5: Casting Distortion Task 6: Technology Transfer
Charles E. Bates; Harry E. Littleton; Don Askeland; Taras Molibog; Jason Hopper; Ben Vatankhah
Land-based turbine casting initiative
DOE Green Energy (OSTI)
To meet goals for the ATS program, technical advances developed for aircraft gas turbine engines need to be applied to land-based gas turbines. These advances include directionally solidified and single crystal castings, alloys tailored to exploit these microstructures, complex internal cooling schemes, and coatings. The proposed program to scale aircraft gas turbine casting technology up to land based gas turbine size components is based on low sulfur alloys, casting process development, post-cast process development, and establishing casting defect tolerance levels. The inspection side is also discussed.
Mueller, B.A.; Spicer, R.A. [Howmet Corp., Whitehall, MI (United States)
Prediction of Part Distortion in Die Casting
The die casting process is one of the net shape manufacturing techniques and is widely used to produce high production castings with tight tolerances for many industries. An understanding of the stress distribution and the deformation pattern of parts produced by die casting will result in less deviation from the part design specification, a better die design and eventually more productivity and cost savings. This report presents methods that can be used to simulate the die casting process in order to predict the deformation and stresses in the produced part and assesses the degree to which distortion modeling is practical for die casting at the current time. A coupled thermal-mechanical finite elements model was used to simulate the die casting process. The simulation models the effect of thermal and mechanical interaction between the casting and the die. It also includes the temperature dependant material properties of the casting. Based on a designed experiment, a sensitivity analysis was conducted on the model to investigate the effect of key factors. These factors include the casting material model, material properties and thermal interaction between casting and dies. To verify the casting distortion predictions, it was compared against the measured dimensions of produced parts. The comparison included dimensions along and across the parting plane and the flatness of one surface.
R. Allen Miller
Emulsion based cast booster - a priming system
This paper explores the potential of emulsion based cast booster to be used as primer to initiate bulk delivered emulsion explosives used in mines. An attempt has been made for comparative study between conventional cast booster and emulsion based cast booster in terms of the initiation process developed and their capability to develop and maintain the stable detonation process in the column explosives. The study has been conducted using a continuous velocity of detonation (VOD) measuring instrument. During this study three blasts have been monitored. In each blast two holes have been selected for study, the first hole being initiated with conventional cast booster while the other one with emulsion based cast booster. The findings of the study advocates that emulsion based cast booster is capable of efficient priming of bulk delivered column explosive with stable detonation process in the column. Further, the booster had advantages over the conventional PETN/TNT based cast booster. 5 refs., 2 figs., 1 tab., 1 photo.
Gupta, R.N.; Mishra, A.K. [National Institute of Rock Mechanics, KGF (India)
Nondestructive Evaluation: Cast Austenitic Stainless Steel Study
This report documents the status of a number of projects that were initiated to support the Cast Austenitic Stainless Steel Roadmap. The majority of these projects fall within the purview of the Research Technical Advisory Committee. These multiyear and multifaceted projects address a number of important issues dealing with cast stainless steel and other emerging industry needs. The first objective of the project is to maintain the cast austenitic stainless steel (CASS) roadmap that outlines an ...
A Benchmark Study on Casting Residual Stress
Stringent regulatory requirements, such as Tier IV norms, have pushed the cast iron for automotive applications to its limit. The castings need to be designed with closer tolerances by incorporating hitherto unknowns, such as residual stresses arising due to thermal gradients, phase and microstructural changes during solidification phenomenon. Residual stresses were earlier neglected in the casting designs by incorporating large factors of safety. Experimental measurement of residual stress in a casting through neutron or X-ray diffraction, sectioning or hole drilling, magnetic, electric or photoelastic measurements is very difficult and time consuming exercise. A detailed multi-physics model, incorporating thermo-mechanical and phase transformation phenomenon, provides an attractive alternative to assess the residual stresses generated during casting. However, before relying on the simulation methodology, it is important to rigorously validate the prediction capability by comparing it to experimental measurements. In the present work, a benchmark study was undertaken for casting residual stress measurements through neutron diffraction, which was subsequently used to validate the accuracy of simulation prediction. The stress lattice specimen geometry was designed such that subsequent castings would generate adequate residual stresses during solidification and cooling, without any cracks. The residual stresses in the cast specimen were measured using neutron diffraction. Considering the difficulty in accessing the neutron diffraction facility, these measurements can be considered as benchmark for casting simulation validations. Simulations were performed using the identical specimen geometry and casting conditions for predictions of residual stresses. The simulation predictions were found to agree well with the experimentally measured residual stresses. The experimentally validated model can be subsequently used to predict residual stresses in different cast components. This enables incorporation of the residual stresses at the design phase along with external loads for accurate predictions of fatigue and fracture performance of the cast components.
Johnson, Eric M. [John Deere -- Moline Tech Center; Watkins, Thomas R [ORNL; Schmidlin, Joshua E [ORNL; Dutler, S. A. [MAGMA Foundry Technologies, Inc.
Ma'aden Open Mould Casting Machines
The paper will describe Ma'aden experience in ingot casting machines: commissioning and start-up, the challenges faced specially with De-molding machines,�...
High Speed Single Crystal Casting Technique
and regulation of convection ... produced by an ordinary casting method because the solidification time is so long as to .... Water Cooled Chillplate. 1 t'Elevator.
Conventional Turbine Rotor Production & Need for Ingot Casting Innovation. The production of large gas turbine rotor forgings made from high temperature�...
Modeling of Casting, Welding, and Advanced Solidification ...
... Evolution of Nodular Cast Iron for the Case of Automobile Crankshaft by the Croning Process [pp. .... Numerical Simulation Steam Generator Repairs [pp.
VIDEO: Manufacture and Casting of Superalloys - TMS
Apr 27, 2007 ... This video gives a basic look at the equipment and operations in the manufacture and casting of superalloys. CITATION: Dr. Alan Partridge,�...
Shape Casting: 5th International Symposium
A Draft Melting Procedure for Al alloys � Additive Manufacturing Supports the Production of Complex Castings � Analysis of Heterogeneous Nucleation in Ductile�...
shape casting: the 2nd international symposium
Modelling the Influence of Multi-Component and Multi-Phase Microstructures on Pore Formation in Cast Aluminum Alloys [pp. 225-232] Peter Lee, Junsheng�...
Multiphase-Field Model for Multicomponent Alloys Coupled to Thermodynamic .... Modeling of Porosity Formation and Feeding Flow in Steel Casting [pp.
ductility prediction for magnesium casting using microstructure ...
Jul 20, 2012 ... Dog-bone shaped AM50 casting samples are used in the experimental part of the work. The experimentally quantified pore characteristics are�...
High Temperature Deformation of Inconel 718 Castings
the computer model to yield the predicted cooling history of the casting, determine the numerically ... 10% HN03, and 5% acetic acid. Figure 1 shows a typical�...
ARTICLES: Investment Casting of Superalloys - TMS
Feb 15, 2007 ... The directory below provides citation information and links to a number of articles on investment casting of superalloys which have been�...
Grain Refinement, Alloying, Solidification and Shape Casting
Feb 16, 2010 ... Bars 200 mm long with a double T cross section (suitable for tensile testing) were sand cast under controlled processing conditions. Chillers of�...
Cast Aluminum Housings in Electrical Fires
Abstract Scope, Cast aluminum and its alloys are often used as enclosures for electrical appliances and similar devices. Electrical faults can often be analyzed�...
CAST SHOP TECHNOLOGY: II: Equipment and Operations
The paper discusses important criteria for the optimum energy and melt rate ... Hydro Aluminium embarked on an extensive R & D thin gauge casting program in�...
Spray casting project final report
Lockheed Martin Energy Systems, Inc. (Energy Systems), along with other participating organizations, has been exploring the feasibility of spray casting depleted uranium (DU) to near-net shape as a waste minimization effort. Although this technology would be useful in a variety of applications where DU was the material of choice, this effort was aimed primarily at gamma-shielding components for use in storage and transportation canisters for high-level radioactive waste, particularly in the Multipurpose Canister (MPC) application. In addition to the waste-minimization benefits, spray casting would simplify the manufacturing process by allowing the shielding components for MPC to be produced as a single component, as opposed to multiple components with many fabrication and assembly steps. In earlier experiments, surrogate materials were used to simulate the properties (specifically reactivity and density) of DU. Based on the positive results from those studies, the project participants decided that further evaluation of the issues and concerns that would accompany spraying DU was warranted. That evaluation occupied substantially all of Fiscal Year 1995, yielding conceptual designs for both an intermediate facility and a production facility and their associated engineering estimates. An intermediate facility was included in this study to allow further technology development in spraying DU. Although spraying DU to near-net shape seems to be feasible, a number of technical, engineering, and safety issues would need to be evaluated before proceeding with a production facility. This report is intended to document the results from the spray-casting project and to provide information needed by anyone interested in proceeding to the next step.
Churnetski, S.R.; Thompson, J.E.
Uranium at Y-12: Casting | Y-12 National Security Complex
Casting Uranium at Y-12: Casting Posted: July 22, 2013 - 3:42pm | Y-12 Report | Volume 10, Issue 1 | 2013 Buttons and other recycled metal are used in casting components for...
Blast casting requires fresh assessment of methods
The article says that because blast casting differs from conventional blasting, our ideas about explosive products, drilling, and initiating methods must change. The author discusses how to select a casting explosive and what factors are important in its selection. He also looks at how to determine the best blasthole diameter and burden blasting pattern.
Subcritical Measurments Multiple HEU Metal Castings
Experiments with the standard annular highly enriched uranium (HEU) metal castings at the Y-12 National Security Complex were performed in which up to five castings ({approx}90 kg) were assembled in a tightly packed array with minimal spacing between castings. The fission chain multiplication process was initiated by a time-tagged {sup 252}Cf spontaneously fissioning neutron source or by time and directionally tagged neutrons from a small portable DT neutron generator. The prompt neutron time behavior was measured with plastic scintillation detectors sensitive to the fast neutron (>1 MeV) and gamma ray without distinction. These experiments were performed to provide data to benchmark methods for the calculation of the prompt neutron time behavior. Previous measurements with a single casting have been reported. This paper presents the experimental results for multiple castings.
Mihalczo, John T [ORNL; Archer, Daniel E [ORNL; Wright, Michael C [ORNL; Mullens, James Allen [ORNL
Cost of Poor Quality in Aluminium Cast House Processes
Symposium, Cast Shop for Aluminum Production. Presentation Title, Cost of Poor Quality in Aluminium Cast House Processes. Author(s), Narasimharaghavan�...
Estimation of Heat Transfer Coefficient in Squeeze Casting of ...
The casting-die interfacial heat transfer coefficient(IHTC) in 5-step casting was .... from First-Principles: Solid-Solution Strengthening, Softening, and Cross-Slip.
Mechanical Properties of Counter-gravity Cast IN718
Key Words: Counter-gravity, investment casting, superalloys, IN718, inert ... using the Counter-gravity Low-pressure Inert-atmosphere (CLI) investment casting�...
Characterization of Technetium Speciation in Cast Stone
This report describes the results from laboratory tests performed at Pacific Northwest National Laboratory (PNNL) for the U.S. Department of Energy (DOE) EM-31 Support Program (EMSP) subtask, �Production and Long-Term Performance of Low Temperature Waste Forms� to provide additional information on technetium (Tc) speciation characterization in the Cast Stone waste form. To support the use of Cast Stone as an alternative to vitrification for solidifying low-activity waste (LAW) and as the current baseline waste form for secondary waste streams at the Hanford Site, additional understanding of Tc speciation in Cast Stone is needed to predict the long-term Tc leachability from Cast Stone and to meet the regulatory disposal-facility performance requirements for the Integrated Disposal Facility (IDF). Characterizations of the Tc speciation within the Cast Stone after leaching under various conditions provide insights into how the Tc is retained and released. The data generated by the laboratory tests described in this report provide both empirical and more scientific information to increase our understanding of Tc speciation in Cast Stone and its release mechanism under relevant leaching processes for the purpose of filling data gaps and to support the long-term risk and performance assessments of Cast Stone in the IDF at the Hanford Site.
Um, Wooyong; Jung, Hun Bok; Wang, Guohui; Westsik, Joseph H.; Peterson, Reid A.
Caste Structures and E-Governance in a Developing Country
Castes, or endogamous kinship relationships, are prevalent in communities across the world and particularly in developing countries. Caste plays a strong role in determining community structures and political power. However, the role of caste as a factor ... Keywords: India, Structuration, caste, development, e-governance, technology
Rahul De'
Advances in Metal Casting Technologies: Materials & Methods
High Temperature Mechanical Properties of Fe-19Cr-13Ni Based Heat Resistant Cast Steel: Doo Hyun Kim1; Wee-Do Yoo1; Jong Hoon Lee1; 1Korea Institute�...
Methods and apparatuses for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics
Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.
Stoddard, Nathan G. (Gettysburg, PA)
National Metal Casting Research Institute final report. Volume 2, Die casting research
Four subprojects were completed: development and evaluation of die coatings, accelerated die life characterization of die materials, evaluation of fluid flow and solidification modeling programs, selection and characterization of Al-based die casting alloys, and influence of die materials and coatings on die casting quality.
Jensen, D. [University of Northern Iowa, Cedar Falls, IA (United States). Dept. of Industrial Technology] [comp.
Compound cast product and method for producing a compound cast product
A compound cast product is formed in a casting mold (14) having a mold cavity (16) sized and shaped to form the cast product. A plurality of injectors (24) is supported from a bottom side (26) of the casting mold (14). The injectors (24) are in fluid communication with the mold cavity (16) through the bottom side (26) of the casting mold (14). A molten material holder furnace (12) is located beneath the casting mold (14). The holder furnace (12) defines molten material receiving chambers (36) configured to separately contain supplies of two different molten materials (37, 38). The holder furnace (12) is positioned such that the injectors (24) extend downward into the receiving chamber (36). The receiving chamber (36) is separated into at least two different flow circuits (51, 52). A first molten material (37) is received in a first flow circuit (51), and a second molten material (38) is received into a second flow circuit (52). The first and second molten materials (37, 38) are injected into the mold cavity (16) by the injectors (24) acting against the force of gravity. The injectors (24) are positioned such that the first and second molten materials (37, 38) are injected into different areas of the mold cavity (16). The molten materials (37, 38) are allowed to solidify and the resulting compound cast product is removed from the mold cavity (16).
Meyer, Thomas N. (3987 Murray Highlands Cir., Murrysville, PA 15668-1747); Viswanathan, Srinath (1104 Albermarle La., Knoxville, TN 37923)
Enhancements in Magnesium Die Casting Impact Properties
The need to produce lighter components in transportation equipment is the main driver in the increasing demand for magnesium castings. In many automotive applications, components can be made of magnesium or aluminum. While being lighter, often times the magnesium parts have lower impact and fatigue properties than the aluminum. The main objective of this study was to identify potential improvements in the impact resistance of magnesium alloys. The most common magnesium alloys in automotive applications are AZ91D, AM50 and AM60. Accordingly, these alloys were selected as the main candidates for the study. Experimental quantities of these alloys were melted in an electrical furnace under a protective atmosphere comprising sulfur hexafluoride, carbon dioxide and dry air. The alloys were cast both in a permanent mold and in a UBE 315 Ton squeeze caster. Extensive evaluation of tensile, impact and fatigue properties was conducted at CWRU on permanent mold and squeeze cast test bars of AZ91, AM60 and AM50. Ultimate tensile strength values between 20ksi and 30ksi were obtained. The respective elongations varied between 25 and 115. the Charpy V-notch impact strength varied between 1.6 ft-lb and 5 ft-lb depending on the alloy and processing conditions. Preliminary bending fatigue evaluation indicates a fatigue limit of 11-12 ksi for AM50 and AM60. This is about 0.4 of the UTS, typical for these alloys. The microstructures of the cast specimens were investigated with optical and scanning electron microscopy. Concomitantly, a study of the fracture toughness in AM60 was conducted at ORNL as part of the study. The results are in line with values published in the literature and are representative of current state of the art in casting magnesium alloys. The experimental results confirm the strong relationship between aluminum content of the alloys and the mechanical properties, in particular the impact strength and the elongation. As the aluminum content increases from about 5% in AM50 to over 9% in AZ91, more of the intermetallic Mg17Al12 is formed in the microstructure. For instance, for 15 increase in the aluminum content from AM50 to AM60, the volume fraction of eutectic present in the microstructure increases by 35%! Eventually, the brittle Mg17Al12 compound forms an interconnected network that reduces ductility and impact resistance. The lower aluminum in AM50 and AM60 are therefore a desirable feature in applications that call for higher impact resistance. Further improvement in impact resistance depends on the processing condition of the casting. Sound castings without porosity and impurities will have better mechanical properties. Since magnesium oxidizes readily, good melting and metal transfer practices are essential. The liquid metal has to be protected from oxidation at all times and entrainment of oxide films in the casting needs to be prevented. In this regard, there is evidence that us of vacuum to evacuate air from the die casting cavity can improve the quality of the castings. Fast cooling rates, leading to smaller grain size are beneficial and promote superior mechanical properties. Micro-segregation and banding are two additional defect types often encountered in magnesium alloys, in particular in AZ91D. While difficult to eliminate, segregation can be minimized by careful thermal management of the dies and the shot sleeve. A major source of segregation is the premature solidification in the shot sleeve. The primary solid dendrites are carried into the casting and form a heterogeneous structure. Furthermore, during the shot, segregation banding can occur. The remedies for this kind of defects include a hotter shot sleeve, use of insulating coatings on the shot sleeve and a short lag time between pouring into the shot sleeve and the shot.
David Schwam; John F. Wallace; Yulong Zhu; Srinath Viswanathan; Shafik Iskander
The industrial ecology of the iron casting industry
Metal casting is an energy and materials intensive manufacturing process, which is an important U.S. industry. This study analyzes iron casting, in particular, for possible improvements that will result in greater efficiencies ...
Jones, Alissa J. (Alissa Jean)
Properties of RS5 and Other Superalloys Cast Using Thermally ...
investment casting methods. The characteristics of ... K.A. Green, M. McLean, S. Olson, and J.J. Schirra ... used to evaluate the soundness of investment castings.
Heat Treatment of High Pressure Die Castings; Challenges and ...
High Strength Aluminum Brazing Sheets for Condenser Fins of Automotive Heat Exchangers � High Temperature Creep Characterization of A380 Cast�...
Comparison of Wax and 3D Printed Investment Casting Pattern ...
About this Abstract. Meeting, Materials Science & Technology 2012. Symposium, Advances in Metal Casting Technologies. Presentation Title, Comparison of�...
Polycrystalline Grain Controlled Castings for Rotating Compressor ...
X-ray and zyglo quality were found to be satisfactory. Subsequently,. Grainex as well as conventionally cast Mod 5A rotors .... ture limited and sizing is often limited by tensile strength related burst ... of cooling gamma prime, and small discrete.
Metallic Fuel Casting Development and Parameter Optimization Simulations
One of the advantages of metallic fuel is the abilility to cast the fuel slugs to near net shape with little additional processing. However, the high aspect ratio of the fuel is not ideal for casting. EBR-II fuel was cast using counter gravity injection casting (CGIC) but, concerns have been raised concerning the feasibility of this process for americium bearing alloys. The Fuel Cycle Research and Development program has begun developing gravity casting techniques suitable for fuel production. Compared to CGIC gravity casting does not require a large heel that then is recycled, does not require application of a vacuum during melting, and is conducive to re-usable molds. Development has included fabrication of two separate benchscale, approximately 300 grams, systems. To shorten development time computer simulations have been used to ensure mold and crucible designs are feasible and to identify which fluid properties most affect casting behavior and therefore require more characterization.
R.S. Fielding; J. Crapps; C. Unal; J.R. Kennedy
Process for slip casting textured tubular structures
A process for centrifugal slip casting a textured hollow tube. A slip made up of a carrier fluid and a suspended powder is introduced into a porous mold which is rotated at a speed sufficient to create a centrifugal force that forces the slip radially outward toward the inner surface of the mold. The suspended powder, which is formed of particles having large dimensional aspect ratios such as particles of superconductive BSCCO, settles in a textured fashion radially outward toward the mold surface. The carrier fluid of the slip passes by capillary action radially outward around the settled particles and into the absorbent mold. A layer of mold release material is preferably centrifugally slip cast to cover the mold inner surface prior to the introduction of the BSCCO slip, and the mold release layer facilitates removal of the BSCCO greenbody from the mold without fracturing.
Steinlage, Greg A. (West Lafayette, IN); Trumble, Kevin P. (West Lafayette, IN); Bowman, Keith J. (West Lafayette, IN)
Solar axion search with the CAST experiment
The CAST (CERN Axion Solar Telescope) experiment is searching for solar axions by their conversion into photons inside the magnet pipe of an LHC dipole. The analysis of the data recorded during the first phase of the experiment with vacuum in the magnet pipes has resulted in the most restrictive experimental limit on the coupling constant of axions to photons. In the second phase, CAST is operating with a buffer gas inside the magnet pipes in order to extent the sensitivity of the experiment to higher axion masses. We will present the first results on the $^{4}{\\rm He}$ data taking as well as the system upgrades that have been operated in the last year in order to adapt the experiment for the $^{3}{\\rm He}$ data taking. Expected sensitivities on the coupling constant of axions to photons will be given for the recent $^{3}{\\rm He}$ run just started in March 2008.
CAST Collaboration; E. Arik; S. Aune; D. Autiero; K. Barth; A. Belov; B. Beltr�n; S. Borghi; F. S. Boydag; H. Br�uninger; G. Cantatore; J. M. Carmona; S. A. Cetin; J. I. Collar; T. Dafni; M. Davenport; L. Di Lella; O. B. Dogan; C. Eleftheriadis; N. Elias; G. Fanourakis; E. Ferrer-Ribas; H. Fischer; J. Franz; J. Gal�n; E. Gazis; T. Geralis; I. Giomataris; S. Gninenko; H. G�mez; M. Hasinoff; F. H. Heinsius; I. Hikmet; D. H. H. Hoffmann; I. G. Irastorza; J. Jacoby; K. Jakov?i?; D. Kang; T. Karageorgopoulou; M. Karuza; K. K�nigsmann; R. Kotthaus; M. Kr?mar; K. Kousouris; M. Kuster; B. Laki?; C. Lasseur; A. Liolios; A. Ljubi?i?; V. Lozza; G. Lutz; G. Luz�n; D. Miller; J. Morales; T. Niinikoski; A. Nordt; A. Ortiz; T. Papaevangelou; M. J. Pivovaroff; A. Placci; G. Raiteri; G. Raffelt; H. Riege; A. Rodr�guez; J. Ruz; I. Savvidis; Y. Semertzidis; P. Serpico; S. K. Solanki; R. Soufli; L. Stewart; M. Tsagri; K. van Bibber; J5D. Villar; J. Vogel; L. Walckiers; K. Zioutas
This report documents the status of a project that was initiated in part to support the Change Initiative associated with PWR Stainless Steel NDE Capability and Performance Demonstration Initiative, but it also falls in line with a project funded through the Electric Power Research Institute's (EPRI's) Technical Innovation program. This multiyear and multifaceted project addresses important issues dealing with cast stainless steel and other emerging industry needs. The first objective of the project is t...
Thin Wall Cast Iron: Phase II
The development of thin-wall technology allows the designers of energy consuming equipment to select the most appropriate material based on cost/material properties considerations, and not solely on density. The technology developed in this research project will permit the designers working for the automotive industry to make a better informed choice between competing materials and thin wall cast iron, thus decreasing the overall cost of the automobile.
Doru M. Stefanescu
This report documents the status of a project that was initiated in part to support the Change Initiative associated with the PWR Stainless Steel Nondestructive Evaluation Capability and Performance Demonstration Initiative and also falls in line with a project currently funded through the Electric Power Research Institute EPRI Program on Technology Innovation. This multiyear, multifaceted project addresses important issues dealing with cast stainless steel and other emerging industry needs. The first ob...
A process for making an aqueous magnesium oxide slip casting slurry comprising the steps of mixing finely ground fused magnesium oxide with water, milling the slurry for at least 30 hours at a temperature of 2-10 deg C (the low temperature during milling inhibiting the formation of hydrated magnesium oxide), discharging the slurry from the mill, adding hydrochloric acid as a deflocculent, and adding a scum inhibitor is presented. (AEC)
Stoddard, S.D.; Nuckolls, D.E.
Seal welded cast iron nuclear waste container
This invention identifies methods and articles designed to circumvent metallurgical problems associated with hermetically closing an all cast iron nuclear waste package by welding. It involves welding nickel-carbon alloy inserts which are bonded to the mating plug and main body components of the package. The welding inserts might be bonded in place during casting of the package components. When the waste package closure weld is made, the most severe thermal effects of the process are restricted to the nickel-carbon insert material which is far better able to accommodate them than is cast iron. Use of nickel-carbon weld inserts should eliminate any need for pre-weld and post-weld heat treatments which are a problem to apply to nuclear waste packages. Although the waste package closure weld approach described results in a dissimilar metal combination, the relative surface area of nickel-to-iron, their electrochemical relationship, and the presence of graphite in both materials will act to prevent any galvanic corrosion problem.
Filippi, Arthur M. (Pittsburgh, PA); Sprecace, Richard P. (Murrysville, PA)
A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leach indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste form. The thermal analyses completed in this study provide some preliminary insight, although the limited
Fox, K.; Edwards, T.; Roberts, K.
Fox, K.; Roberts, K.; Edwards, T.
Practice of overburden casting at the Trapper Mine - Craig, Colorado
Enfield Pit was chosen to test overburden casting at the Trapper Mine in Colorado. Seam and overburden geology, and drilling and blasting patterns are described. Tables summarize the costs involved in cast blasting. The primary problem encountered was coal losses along the open face due to high powder factors and heave of the overburden. It was concluded that cast blasting has the potential of considerable savings in overburden stripping. 3 figures, 2 tables.
Dupree, P.D.
Advances in Metal Casting Technologies - Molding, Properties and ...
Oct 9, 2012 ... Shot Blasting is a practice commonly used in the metal casting industry to remove sand, small particulates and peen surface. In this experiment�...
Simulation of Aluminum Shape Casting Processing: From Alloy - TMS
Sep 24, 2007 ... "The objective of the TMS Symposium on the "Simulation of Aluminum Shape Casting Processing" From Alloy Design to Mechanical Properties"�...
Effect of Centrifugal And Gravity Casting Technique over ...
In this work an attempt is made to study the effect of centrifugal and gravity casting ... A Minimum Pollution, Low Energy Process for the Recovery of Cobalt and�...
Prediction of Residual Stress in Grey Cast Iron: Experiment and ...
Effect of Casting Conditions on Microstructural Evolution and ...
Mold Fluxes for Continuous Casting of Steels with High Aluminum ...
Optimizing the Squeeze Casting Process of Carbon Fiber ...
Main Factors Influencing the Qualitative Properties of Casts in the ...
Continuous Casting Simulation of 2304 Duplex Stainless Steel Via ...
Presentation Title, Continuous Casting Simulation of 2304 Duplex Stainless Steel Via ... Applications of Thermo-Chemical and Thermo-Physical Models in the�...
Electron Beam Cold Hearth Refining of Investment Casting ...
Electron Beam Cold Hearth Refining of Investment Casting Superalloys in a Large Production EB Furnace. Janine C. Borofka. Axe1 Johnson Metals, Inc.
Visualization for Runner System Design in Die Casting.
??The research focuses on the development of a die casting runner system design process, and the visualization of this process. It provides a simple and� (more)
Ning, Zhaohui
Effect of Casting Speed on Temperature Difference between Copper ...
DRI Carburization in the Reduction and Transition Zones of a Shaft Furnace MIDREX Type � Effect of Casting Speed on Temperature Difference between�...
Interplay of Flow and Solidification in a Horizontal Centrifugal Casting
Microstructure Characterization of Welds in a Haynes 282 Casting
Corrosion and Materials Degradation in Microturbines � Development of Cast Alumina-Forming Austenitic Stainless Steel Alloys � Effect of Al-Substitution and�...
Impact of Casting Superheat on the Mechanical Properties of ...
Residual Stresses in Semi-permanent Mold Engine Head Castings
One casting was quenched using water and the other was air quenched. ... the intake and exhaust valve ports indicating the main differences in strain/stress�...
Improving Pouring Technology of Large Steel Castings by Using ...
Hydrogen Embrittlement of Cast Alloy 718 Effects of ...
HYDROGEN EMBRITTLEMENT OF CAST ALLOY 718. EFFECTS OF. HOMOGENIZATION, GRAIN SIZE AND &PHASE. Giiran sjoberg* and Daniel c o r m * *.
Analyzing Casting Problems by the On-line Monitoring of ...
In these instances, the control system initiates an automatic termination of the cast .... from the DSPC operating management, operating crews, maintenance staff�...
The Sensitivity of Investment Casting Simulations to the Accuracy of ...
THE SENSITIVITY OF INVESTMENT CASTING SIMULATIONS TO THE ACCURACY OF. THERMOPHYSICAL PROPERTY VALUES. X. L. Yang1, P. D. Lee1,�...
Impact and Fracture Toughness of Investment Cast, Plasma Sprayed ...
Impact and Fracture Toughness of Investment Cast,. Plasma Sprayed, and Wrought Alloy 718. G. K. Bouse. Howmet Corporation. Operhall Research Center .
Development of a Improved Heat Treatment for Investment Cast ...
Development of a Improved Heat Treatment for Investment Cast Inconel718 ( PWA 649). John J. Schirra. United Technologies Corporation - Pratt & Whitney.
Characterization of the Dendritic Microstructure of Investment Cast ...
CHARACTERIZATION OF THE DENDRITIC MICROSTRUCTURE. OF INVESTMENT CAST ALLOY 718. Y.K. Ko and J.T. Berry. Department of Metallurgical and.
Microstructure Analysis of Fine Grain Alloy 718 Casting
Investment castings of superalloys such as alloy 718 have been used for many years in radial turbine wheels( I-3). Development of techniques to minimize�...
Cast Shop for Aluminum Production - Programmaster.org
Jul 31, 2012 ... Advanced Compact Filter: ( ACF) An Efficient and Flexible Filtration Process � AlTi5B1 Grain Refiners on the Casting of DIN 226 Aluminum�...
An Investigation of Microstructure and HAZ Microfissuring of Cast ...
Bristol Aerospace Ltd., Winnipeg, Manitoba, Canada. Abstract. The effect of microstructure on the HAZ of cast a.lloy 7 18 has been examined in this study.
Niobium Alloying in Grey Cast Iron for Vehicle Brake Discs
Presentation Title, Niobium Alloying in Grey Cast Iron for Vehicle Brake Discs. Author(s) ... Microtexture Analysis of a Hot Rolled Silicon Electric Steel � Niobium
Casting simulation software cuts energy use and waste generation ...
Casting simulation software cuts energy use and waste generation in half. Caterpillar Inc. Peoria, IL. Argonne and Caterpillar (Peoria, Ill.) have developed ...
Modeling Coal Seam Damage in Cast Blasting
A discrete element computer program named DMC_BLAST (Distinct Motion Code) has been under development since 1987 for modeling rock blasting (Preece & Taylor, 1989). This program employs explicit time integration and uses spherical or cylindrical elements that are represented as circles in two dimensions. DMC_BLAST calculations compare favorably with data from actual bench blasts (Preece et al, 1993). Coal seam chilling refers to the shattering of a significant portion of the coal leaving unusable fines. It is also refereed to as coal damage. Chilling is caused during a blast by a combination of explosive shock energy and movement of the adjacent rock. Chilling can be minimized by leaving a buffer zone between the bottom of the blastholes and the coal seam or by changing the blast design to decrease the powder factor or by a combination of both. Blast design in coal mine cast blasting is usually a compromise between coal damage and rock fragmentation and movement (heave). In this paper the damage to coal seams from rock movement is examined using the discrete element computer code DMC_BLAST. A rock material strength option has been incorporated into DMC_BLAST by placing bonds/links between the spherical particles used to model the rock. These bonds tie the particles together but can be broken when the tensile, compressive or shear stress in the bond exceeds the defined strength. This capability has been applied to predict coal seam damage, particularly at the toe of a cast blast where drag forces exerted by movement of the overlying rock can adversely effect the top of the coal at the bench face. A simulation of coal mine cast blasting has been performed with special attention being paid to the strength of the coal and its behavior at t he bench face during movement of the overlying material.
Chung, S.H.; Preece, D.S.
Continuation of Crosscutting Technology Development at Cast
This Final Technical Report describes progress made on the sub-projects awarded in the Cooperative Agreement DE-FC26-05NT42457: Continuation of Crosscutting Technology Development at Center for Advanced Separation Technologies (CAST). The final reports for each sub-project are attached in the appendix. Much of the research to be conducted with Cooperative Agreement funds will be longer-term, high-risk, basic research and will be carried out in five broad areas: a) Solid-solid separation b) Solid-liquid separation c) Chemical/Biological Extraction d) Modeling and Control, and e) Environmental Control.
Yoon, Roe-Hoan
Method and apparatus for strip casting
Casting nozzles will provide improved flow conditions with the parameters controlled according to the present invention. The gap relationships between the nozzle slot and exit orifice must be controlled in combination with converging exit passageway to provide a smooth flow without shearing and turbulence in the stream. The nozzle lips are also rounded to improve flow and increase refractory life of the lips of the nozzle. The tundish walls are tapered to provide improve flow for supplying the melt to the nozzle. The nozzle is located about 45[degree] below top dead center for optimum conditions. 2 figures.
Follstaedt, D.W.; Powell, J.C.; Sussman, R.C.; Williams, R.S.
Reconciling the CAST and PVLAS Results
The PVLAS experiment has recently claimed evidence for an axion-like particle in the milli-electron-Volt mass range with a coupling to two photons that appears to be in contradiction with the negative results of the CAST experiment searching for solar axions. The simple axion interpretation of these two experimental results is therefore untenable and it has posed a challenge for theory. We propose a possible way to reconcile these two results by postulating the existence of an ultralight pseudo-scalar particle interacting with two photons and a scalar boson and the existence of a low scale phase transition in the theory.
R. N. Mohapatra; Salah Nasri
The PVLAS experiment has recently claimed evidence for an axionlike particle in the milli-electron-volt mass range with a coupling to two photons that appears to be in contradiction with the negative results of the CAST experiment searching for solar axions. The simple axion interpretation of these two experimental results is therefore untenable and it has posed a challenge for theory. We propose a possible way to reconcile these two results by postulating the existence of an ultralight pseudoscalar particle interacting with two photons and a scalar boson and the existence of a low scale phase transition in the theory.
Mohapatra, R. N. [Department of Physics, University of Maryland, College Park, Maryland 20742 (United States); Nasri, Salah [Department of Physics, University of Florida, Gainesville, Florida 32611 (United States)
Material development in the SI sub 3 N sub 4 system using glass encapsulated Hip'ing
This report covers a two-year program to develop fully dense Si{sub 3}N{sub 4} matrix SiC whisker composites with enhanced properties over monolithic Si{sub 3}N{sub 4} materials. The primary goal was to develop a composite with a fracture toughness > 10 MPa{radical}m, capable of using high pressure glass encapsulated HIP'ing. Coating methods were developed to apply thin (<150nm) stoichiometric BN layers to SiC whiskers and also to apply a dual coating of SiC over carbon to the whiskers. Fracture toughness of the composites was determined to increase as the quantity of whiskers (or elongated grains) with their axis perpendicular to the crack plane increased. Of the interface compositions evaluated in this effort, carbon was determined to be the most effective for increasing toughness. The highest toughnesses (6.8--7.0 MPa{radical}m) were obtained with uniaxially aligned carbon coated whiskers. There was no evidence of the carbon coating compromising the oxidation resistance of the composites at 1370{degree}C.
Corbin, N.D.; Sundberg, G.J.; Siebein, K.N.; Willkens, C.A.; Pujari, V.K.; Rossi, G.A.; Hansen, J.S.; Chang, C.L.; Hammarstrom, J.L.
Effect of Casting Conditions and Composition on Microstructural Gradients in Roll Cast Aluminum Alloys
Twin Roll Casting (TRC) is a process by which thin strip is produced directly from molten metal. This process has many advantages over traditional Direct Chill (DC) casting where metal is cast into large slabs or ingots and subsequently hot and cold rolled into strips. While the DC casting involves large capital investment and energy consumption, TRC produces strip with thickness in the range of 10 mm to 2.5 mm in one operation without hot rolling, with less cost, energy usage and equipment requirements. In TRC AA3105, high solidification and post-solidification cooling rates lead to high manganese supersaturation throughout the as-cast strip and very fine constituent particles near strip surface. After 90% cold rolling, the TRC material shows sluggish recrystallization kinetics and a very coarse grain structure, due to concurrent forming dispersoids and/or fine constituent particles. These particles interfere with the nucleation process by preventing migration of the boundaries associated with potential nuclei, resulting in fewer recrystallization nuclei and slower nucleation rate. In addition, the fine particles can impede grain growth by exerting a pinning pressure on moving boundaries. The current study investigated the microstructure evolution in TRC AA3105 during different thermo-mechanical treatments. A systematic study of the effects of different homogenization treatments on second phase particles was carried out. The heating rate effect on recrystallization was studies using an infrared heating furnace. The effect of second phase particles on recrystallization behavior was summarized and experimental results were presented. It was shown that a desirable, fine recrystallized grain size could be obtained by either of two means- rapid heating rate ot the annealing tempeature, or by a pre-cold work homogenization heat treatment.
Burton R. Patterson
Horizontal electromagnetic casting of thin metal sheets
Thin metal sheets are cast by magnetically suspending molten metal deposited within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled to form a solid metal sheet. Magnetic flux increases as the molten metal sheet moves downward and decreases as the molten metal sheet moves upward to stabilize the sheet and maintain it in equilibrium as it is linearly displaced and solidified by cooling gases. A conducting shield is electrically coupled to the molten metal sheet by means of either metal sheet engaging rollers or brushes on the solidified metal, and by means of an electrode in the vessel containing the molten metal thereby providing a return path for the eddy currents induced in the metal sheet by the AC coil generated magnetic flux. Variation in the geometry of the conducting shield allows the magnetic flux between the metal sheet and the conducting shield to be varied and the thickness in surface quality of the metal sheet to be controlled. Side guards provide lateral containment for the molten metal sheet and stabilize and shape the magnetic field while a leader sheet having electromagnetic characteristics similar to those of the metal sheet is used to start the casting process and precedes the molten metal sheet through the magnet and forms a continuous sheet therewith. The magnet may be either U-shaped with a single racetrack coil or may be rectangular with a pair of facing bedstead coils.
Hull, John R. (Hinsdale, IL); Lari, Robert J. (Aurora, IL); Praeg, Walter F. (Palos Park, IL); Turner, Larry R. (Naperville, IL)
Semi-supervised cast indexing for feature-length films
Cast indexing is a very important application for content-based video browsing and retrieval, since the characters in feature-length films and TV series are always the major focus of interest to the audience. By cast indexing, we can discover the main ...
Wei Fan; Tao Wang; JeanYves Bouguet; Wei Hu; Yimin Zhang; Dit-Yan Yeung
A boosting discriminative model for moving cast shadow detection
Moving cast shadow causes serious problem while segmenting and extracting foreground from image sequences, due to the misclassification of moving shadow as foreground. This paper proposes a boosting discriminative model for moving cast shadow detection. ... Keywords: boosting, discriminative random fields, graph cut, shadow detection
Yufei Zha; Ying Chu; Duyan Bi
Casting Porosity-Free Grain Refined Magnesium Alloys
The objective of this project was to identify the root causes for micro-porosity in magnesium alloy castings and recommend remedies that can be implemented in production. The findings confirm the key role played by utilizing optimal gating and risering practices in minimizing porosity in magnesium castings.?
Schwam, David [Case Western Reserve University] [Case Western Reserve University
Bendix now makes four component parts for one precision mechanical assembly from investment castings rather than from wrought-stock machined and welded assemblies--a conversion based directly on the cost saving potential. With proper evaluation of metal components for casting suitability and usage, manufacturers may realize cost saving far beyond their expectations.
Cromwell, W. E.; Tiehen, G. L.; Paul, J. P.
Manufacturers Saving with Lost Foam Metal Casting | Department of Energy
Manufacturers Saving with Lost Foam Metal Casting Manufacturers Saving with Lost Foam Metal Casting Manufacturers Saving with Lost Foam Metal Casting December 18, 2009 - 2:43pm Addthis Eric Barendsen Energy Technology Program Specialist, Office of Energy Efficiency and Renewable Energy What are the key facts? Metal casting was identified as one of the top 10 energy users in manufacturing. The technology represents a 20- to 25-percent reduction in production costs and uses 7 percent fewer materials than traditional processes. One example of this technology is being used by General Motors to make lightweight engine blocks for the fuel-efficient vehicles they manufacture. A government-funded effort to support development of foam metal casting helped reduce an estimated 9.4 million tons of solid waste between 1994 and 2005, which saved industry an estimated 3 trillion Btu.
Tensile-property characterization of thermally aged cast stainless steels
The effect of thermal aging on tensile properties of cast stainless steels during service in light water reactors has been evaluated. Tensile data for several experimental and commercial heats of cast stainless steels are presented. Thermal aging increases the tensile strength of these steels. The high-C Mo-bearing CF-8M steels are more susceptible to thermal aging than the Mo-free CF-3 or CF-8 steels. A procedure and correlations are presented for predicting the change in tensile flow and yield stresses and engineering stress-vs.-strain curve of cast stainless steel as a function of time and temperature of service. The tensile properties of aged cast stainless steel are estimated from known material information, i.e., chemical composition and the initial tensile strength of the steel. The correlations described in this report may be used for assessing thermal embrittlement of cast stainless steel components.
Michaud, W.F.; Toben, P.T.; Soppet, W.K.; Chopra, O.K. [Argonne National Lab., IL (United States)
Solar Cells: Spin-Cast Bulk Heterojunction Solar Cells: A Dynamical...
Solar Cells: Spin-Cast Bulk Heterojunction Solar Cells: A Dynamical Investigation Solar Cells: Spin-Cast Bulk Heterojunction Solar Cells: A Dynamical Investigation Print Wednesday,...
A Study on Applicastion of the Squeeze Casting Process to the ...
Therefore, in this study, squeeze casting was introduced to substitute die casting process for the large Al motor rotor. Numerical analysis was performed to�...
Method of casting silicon into thin sheets
Silicon (Si) is cast into thin shapes within a flat-bottomed graphite crucible by providing a melt of molten Si along with a relatively small amount of a molten salt, preferably NaF. The Si in the resulting melt forms a spherical pool which sinks into and is wetted by the molten salt. Under these conditions the Si will not react with any graphite to form SiC. The melt in the crucible is pressed to the desired thinness with a graphite tool at which point the tool is held until the mass in the crucible has been cooled to temperatures below the Si melting point, at which point the Si shape can be removed.
Sanjurjo, Angel (San Jose, CA); Rowcliffe, David J. (Los Altos, CA); Bartlett, Robert W. (Tucson, AZ)
Erosion of white cast irons and stellite
The erosion behavior of dual-phase alloys containing large, hard carbides has been investigated. A series of high Cr-Mo white cast irons with a systematic variation of carbide volume fraction (CVF) and powder metallurgy specimens of Stellite 6 were eroded with alumina, crushed quartz and rounded quartz particles. These erodents were chosen because quartz has a hardness between that of the matrix and the Cr-rich carbides, whereas the hardness of alumina is comparable to that of the carbides. In addition, comparison of the results with crushed quartz and alumina allows an evaluation of the effect of particle hardness while the differences between the rounded and crushed quartz results can be attributed to the shape difference. For all erodents and alloys, the dependence of erosion on angle of incidence was weak. With alumina and rounded quartz erodents, the erosion rate increased with increasing CVF, while the reverse was true with crushed quartz. The crushed quartz erodent gave an erosion rate only slightly lower than that of alumina, indicating that the carbide erosion resistance is not a strong function of erodent particle hardness in this range of hardness. Scanning electron microscope (SEM) observations of the eroded surfaces showed that erosion of the highest-CVF white cast iron alloy with alumina or rounded quartz resulted in depression of the large primary carbides, while with crushed quartz many of the carbides protruded above the matrix. The SEM and erosion rate observations show that with crushed quartz the carbides are more erosion resistant than the eutectic matrix and that the carbides therfore contribute to erosion resistance, while with the other erodents the reverse is true. 17 refs., 15 figs., 2 tabs.
Aptekar, S.S.; Kosel, T.H.
Predicting Pattern Tooling and Casting Dimensions for Investment Casting, Phase III
Efforts during Phase III focused mainly on the shell-alloy systems. A high melting point alloy, 17-4PH stainless steel, was considered. The experimental part of the program was conducted at ORNL and commercial foundries, where wax patterns were injected, molds were invested, and alloys were poured. Shell molds made of fused-silica and alumino-silicates were considered. A literature review was conducted on thermophysical and thermomechanical properties alumino-silicates. Material property data, which were not available from material suppliers, was obtained. For all the properties of 17-4PH stainless steel, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. Thus, some material properties were evaluated using ProCAST, based on CompuTherm database. A comparison between the predicted material property data and measured property data was made. It was found that most material properties were accurately predicted only over several temperature ranges. No experimental data for plastic modulus were found. Thus, several assumptions were made and ProCAST recommendations were followed in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted during heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution on heating and cooling. Numerical simulations were performed using ProCAST for the investment casting of 17-4PH stainless steel parts in fused silica molds using the thermal expansion obtained on heating and another one with thermal expansion obtained on cooling. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The shell mold was considered to be a pure elastic material. The alloy dimensions were obtained from numerical simulations. For 17-4PH stainless steel parts, the alloy shrinkage factors were over-predicted, as compared with experimental data. Additional R&D focus was placed on obtaining material property data for filled waxes, waxes that are common in the industry. For the first time in the investment casting industry, the thermo-mechanical properties of unfilled and filled waxes were measured. Test specimens of three waxes were injected at commercial foundries. Rheometry measurement of filled waxes was conducted at ORNL. The analysis of the rheometry data to obtain viscoelastic properties was not completed due to the reduction in the budget of the project (approximately 50% funds were received).
Sabau, Adrian S [ORNL
Stress Corrosion Cracking Behavior of Cast Stainless Steels
Casting of austenitic stainless steels offers the possibility of directly producing large and/or relatively complex structures, such as the first wall shield modules or the diverter cassette for the ITER fusion reactor. Casting offers major cost savings when compared to fabrication via welding of quarter modules machined from large forgings. However, the strength properties of such cast components are typically considered inferior to those of conventionally forged and annealed components. To improve and validate cast stainless steel as a substitute for wrought stainless steel, a development and testing program was initiated, utilizing nitrogen and manganese additions to promote improved performance. This paper focuses on the response of the first set of developmental alloys to neutron-irradiation and susceptibility to stress corrosion cracking. These cast materials may also have applications for different components in light water reactors. Results showed that all steels exhibited irradiation-induced hardening and a corresponding drop in ductility, as expected, although there is still considerable ductility in the irradiated samples. The cast steels all exhibited reduced hardening in comparison to a wrought reference steels, which may be related to a larger grain size. Higher nitrogen contents did not negatively influence irradiation performance. Regarding stress corrosion cracking susceptibility, the large difference in grain size limits the comparison between wrought and cast materials, and inclusions in a reference and archive cast alloy tests complicate analysis of these samples. Results suggest that the irradiated archive heat was more susceptible to cracking than the modified alloys, which may be related to the more complex microstructure. Further, the results suggest that the modified cast steel is at least as SCC resistant as wrought 316LN. The beneficial effect of nitrogen on the mechanical properties of the alloys remains after irradiation and is not detrimental to SCC resistance.
Teysseyre, Sebastien [University of Michigan; Busby, Jeremy T [ORNL; Was, Gary [University of Michigan
Method to prevent/mitigate steam explosions in casting pits
Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water.
Taleyarkhan, Rusi P. (Knoxville, TN)
Advanced Cast Austenitic Stainless Steels for High Temperature Components
In July of 2002, a Cooperative Research and Development Agreement (CRADA) was undertaken between Oak Ridge National Laboratory (ORNL) and Caterpillar, Inc. (Caterpillar Technical Center) to develop and commercialize new cast stainless steels invented and initially tested on a prior CRADA. This CRADA is a direct follow-on project to CRADA ORNL-99-0533 for diesel engine exhaust component and gas turbine engine structural component applications. The goal of this new CRADA was to develop and commercialize the newly discovered cast stainless steels (primarily CF8C-Plus) with improved performance and reliability, as lower-cost upgrade alternatives to more costly cast Ni-based superalloys.
Maziasz, P.J.; Shingledecker, J.P.; Evans, N.D.; Pollard, M.J. (Caterpillar, Inc.)
Cast Stone is undergoing evaluation as the supplemental treatment technology for Hanford�s (Washington) high activity waste (HAW) and low activity waste (LAW). This report will only cover the LAW Cast Stone. The programs used for this simulated Cast Stone were gradient density change, compressive strength, and salt waste form phase identification. Gradient density changes show a favorable outcome by showing uniformity even though it was hypothesized differently. Compressive strength exceeded the minimum strength required by Hanford and greater compressive strength increase seen between the uses of different salt solution The salt waste form phase is still an ongoing process as this time and could not be concluded.
Kim, Y.
Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water. 3 figs.
Taleyarkhan, R.P.
Report: EM Management Analysis and Strategic Vision-Casting
Management Analysis and Strategic Vision-Casting Management Analysis and Strategic Vision-Casting September 25, 2008 Submitted by the EMAB Strategic Vision-Casting Subcommittee Background: In the course of developing the Environmental Management Advisory Board's (EMAB) fiscal year (FY) 2008 review topics, EM leadership and Board members recognized a need to re-examine the program's strategy and vision for the future, in order to better position EM and continue its momentum for clean-up and closure. This endeavor will also ensure that the next administration and current stakeholders are aligned with EM's proposed priorities, funding requirements, and commitments for 2009 and beyond. Consequently, the Board formed a Strategic Vision-Casting Subcommittee that was charged with the assignment of reviewing EM's current and past missions and strategic visions to assess
Cast Stainless Steel Aging Research Plan | Department of Energy
Cast Stainless Steel Aging Research Plan Cast Stainless Steel Aging Research Plan Cast Stainless Steel Aging Research Plan This work plan proposes to build a systematic knowledge base for the thermal aging behavior of cast stainless steels (CASSs) within a limited time of five years. The final output of execution of the plan is expected to provide conclusive predictions for the integrity of the CASS components of LWR power plants during the extended service life up to and beyond 60 years. Mechanical and microstructural data obtained through accelerated aging experiment and computational simulation will be the key input for the prediction of CASS behaviors and for the integrity analyses for various CASS components. While the accelerated aging experiment and computational simulation results will comprise the main components of the knowledge base
The External and Internal shrinkages in Aluminum Gravity Castings
Presentation Title, The External and Internal shrinkages in Aluminum Gravity Castings. Author(s), Fu-Yuan Hsu, Shin-Wei Wang, Huey-Jiuan Lin. On-Site�...
Mold, flow, and economic considerations in high temperature precision casting
Casting high temperature alloys that solidify through a noticeable two phase region, specifically platinum-ruthenium alloys, is a particularly challenging task due to their high melting temperature and this necessitates ...
Humbert, Matthew S
An Energy Savings Model for the Heat Treatment of Castings
An integrated system of software, databases, and design rules have been developed, verified, and to be marketed to enable quantitative prediction and optimization of the heat treatment of aluminum castings to increase quality, increase productivity, reduce heat treatment cycle times and reduce energy consumption. The software predicts the thermal cycle in critical locations of individual components in a furnace, the evolution of microstructure, and the attainment of properties in heat treatable aluminum alloy castings. The model takes into account the prior casting process and the specific composition of the component. The heat treatment simulation modules can be used in conjunction with software packages for simulation of the casting process. The system is built upon a quantitative understanding of the kinetics of microstructure evolution in complex multicomponent alloys, on a quantitative understanding of the interdependence of microstructure and properties, on validated kinetic and thermodynamic databases, and validated quantitative models.
Y. Rong; R. Sisson; J. Morral; H. Brody
Defect Analysis by Casting Simulation Software in Rolling Roll ...
Direct Numerical Simulation of Inclusion Turbulent Deposition at Liquid ... and Shrinkage Pipe Formation on Macrosegregation of Investment Cast -TiAl Alloys ... of the Interaction between a Foreign Particle an Solidifying Crystalline Interface.
Transport and Entrapment of Particles in Steel Continuous Casting
Direct Numerical Simulation of Inclusion Turbulent Deposition at Liquid ... Flow and Shrinkage Pipe Formation on Macrosegregation of Investment Cast -TiAl Alloys ... Numerical Modeling of the Interaction between a Foreign Particle an�...
Molten Mold Flux Technology for Continuous Casting of the ULC ...
Heat flux from the molten steel to the cupper plate of the casting mold was .... of Conventional and High Niobium API 5L X80 Line Pipe Steel Using EBSD.
Optimizing a Drifter Cast Strategy with a Genetic Algorithm
An experiment design problem�-that of drifter cast strategy�-is discussed. Different optimization techniques used as part of preparations for the Semaphore-93 air-sea experiment, during which drifters were deployed, are examined. The ...
Fabrice Hernandez; Pierre-Yves Le Traon; Norman H. Barth
Shape Casting: The John Campbell Symposium TABLE OF ...
W. Sun, H.E. Littleton, and C.E. Bates. The Five Feeding Mechanisms [pp. 93] ... Pressure in Cast Aluminum Alloys [pp. 113] J.T. Berry, R. Luck, and R.P. Taylor�...
Mikro Systems Develops Unique Ceramic Core Casting Technology...
Office of Science (SC) Website
Mikro Systems, Inc. Ceramic casting core with an intricate, fine-featured trailing edge. R&D Opportunity A key limitation of turbine efficiency has been the failure of parts at...
Methods for manufacturing geometric multi-crystalline cast materials
Methods are provided for casting one or more of a semi-conductor, an oxide, and an intermetallic material. With such methods, a cast body of a geometrically ordered multi-crystalline form of the one or more of a semiconductor, an oxide, and an intermetallic material may be formed that is free or substantially free of radially-distributed impurities and defects and having at least two dimensions that are each at least about 10 cm.
Stoddard, Nathan G
Infofrax: Cbr in fused cast refractory manufacture
Abstract. This paper describes a CBR application in manufacturing industry, a domain where CBR has by and large proved its applicability and success. The paper details a thorough understanding of the field of fused cast manufacturing basically seen from the perspective of glass furnace, where quality of glass produced is straightaway related to the refractory blocks used in furnace linings. The applicability of CBR paradigm is revisited in the present context. The CBR process needed is conceptualized and designed. The paper states in detail the evolution of the system starting from tackling hurdles of the knowledge acquisition and refining, facing a number of pitfalls in the prototype phase, to final implementation of InfoFrax, a CBR system specially devised for the project, and overall description of the same covering architecture, and usage. The paper also reports the immediate effects of the software in form of direct user feedback, expectations from the existing system and some directions of future work already underway in the project. 1
Deepak Khemani; Radhika Selvamani B; A Rabi Dhar; Michael S. M
Secondary Waste Cast Stone Waste Form Qualification Testing Plan
The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is being constructed to treat the 56 million gallons of radioactive waste stored in 177 underground tanks at the Hanford Site. The WTP includes a pretreatment facility to separate the wastes into high-level waste (HLW) and low-activity waste (LAW) fractions for vitrification and disposal. The LAW will be converted to glass for final disposal at the Integrated Disposal Facility (IDF). Cast Stone � a cementitious waste form, has been selected for solidification of this secondary waste stream after treatment in the ETF. The secondary-waste Cast Stone waste form must be acceptable for disposal in the IDF. This secondary waste Cast Stone waste form qualification testing plan outlines the testing of the waste form and immobilization process to demonstrate that the Cast Stone waste form can comply with the disposal requirements. Specifications for the secondary-waste Cast Stone waste form have not been established. For this testing plan, Cast Stone specifications are derived from specifications for the immobilized LAW glass in the WTP contract, the waste acceptance criteria for the IDF, and the waste acceptance criteria in the IDF Permit issued by the State of Washington. This testing plan outlines the testing needed to demonstrate that the waste form can comply with these waste form specifications and acceptance criteria. The testing program must also demonstrate that the immobilization process can be controlled to consistently provide an acceptable waste form product. This testing plan also outlines the testing needed to provide the technical basis for understanding the long-term performance of the waste form in the disposal environment. These waste form performance data are needed to support performance assessment analyses of the long-term environmental impact of the secondary-waste Cast Stone waste form in the IDF
Westsik, Joseph H.; Serne, R. Jeffrey
Method of reducing the green density of a slip cast article
The method disclosed in this specification is one of reducing the green density of an article cast in a slip casting operation. The article is cast from a casting slip containing silicon metal particles, yttrium containing particles, and a small amount of a fluoride salt which is effective to suppress flocculation of the silicon metal particles by y.sup.+3 ions derived from the yttrium containing particles. The method is characterized by the following step. A small amount of compound which produces a cation which will partly flocculate the particles of silicon metal is added to the casting slip. The small amount of this compound is added so that when the casting slip is slip cast into a casting mold, the partly flocculated particles of silicon will interrupt an otherwise orderly packing of the particles of silicon and particles of yttrium. In this manner, the green density of the slip cast article is reduced and the article may be more easily nitrided.
Mangels, John A. (Flat Rock, MI); Dickie, Ray A. (Birmingham, MI)
Twin-belt continuous caster with containment and cooling of the exiting cast product for enabling high-speed casting of molten-center product
In continuously casting molten metal into cast product by a twin-belt machine, it is desirable to achieve dramatic increases in speed (linear feet per minute) at which cast product exits the machine, particularly in installations where steel cast product is intended to feed a downstream regular rolling mill (as distinct from a planetary mill) operating in tandem with the twin-belt caster. Such high-speed casting produces product with a relatively thin shell and molten interior, and the shell tends to bulge outwardly due to metallostatic head pressure of the molten center. A number of cooperative features enable high-speed, twin-belt casting: (1) Each casting belt is slidably supported adjacent to the caster exit pulley for bulge control and enhanced cooling of cast product. (2) Lateral skew steering of each belt provides an effective increase in moving mold length plus a continuity of heat transfer not obtained with prior art belt steering apparatus. (3) The exiting slab is contained and supported downstream from the casting machine to prevent bulging of the shell of the cast product, and (4) spray cooling is incorporated in the exit containment apparatus for secondary cooling of cast product.
Dykes, Charles D. (303 Shore Rd., Milton, VT); Daniel, Sabah S. (303 Shore Rd., Pittsburgh, PA); Wood, J. F. Barry (303 Shore Rd., Burlington, VT 05401)
Casting a Light on California | Department of Energy
Casting a Light on California Casting a Light on California Casting a Light on California October 28, 2010 - 4:00pm Addthis John Schueler John Schueler Former New Media Specialist, Office of Public Affairs What does this project do? Combined, the six projects will produce 2,837 megawatts of energy, enough to power 851,500 to 2.1 million homes, as well as create 3,700 new construction jobs and more than six hundred permanent plant operations positions. Yesterday, Secretary Salazar joined Gov. Arnold Schwarzenegger to celebrate the groundbreaking of the Ivanpah Solar Electric Generating System, an innovative "power tower" project in San Bernardino County, California. Located in Southern California's Mojave Desert, Ivanpah will use solar "power tower" technology to produce up to 370 megawatts of clean,
Ultra Large Castings to Produce Low Cost Aluminum Vehicle Structures
Through a cooperative effort with the U.S. Department of Energy (DOE) Office of Heavy Vehicle Technologies (OHVT), Alcoa is developing a casting process to produce ultra large thin wall components. The casting process is a low pressure, metal mold, multiport injection vertical casting process. The specific system for demonstration of the process is located at Alcoa's Technology Center and will be capable of producing parts extending 3 M long, 1.7 M wide and 0.4 M high. For example, single castings of car floor pan frames or side wall aperture structures are candidates for this installation. This shall provide a major opportunity to reduce the cost of lightweight transportation vehicle structures by (a) reducing the components or part count and (b) reducing the cost of assembly. To develop and demonstrate the process, an inner panel of the Chrysler minivan liftgate will be first produced on this system. Through computer analyses, the cast inner panel design was developed to satisfy both structural performance and casting process requirements. Currently, this is an 11 part assembly of steel components. At the time of this abstract, the numerous system components are in various phases of fabrication and site preparation is fully underway, with system shakedown beginning in the second quarter of 1999. Successful demonstration of caster system operation is anticipated to occur during the third quarter and production of a high quality product during the fourth quarter. Although the process is targeted toward reducing the cost of lightweight trucks, buses and autos, consideration is being given to application in the aircraft industry.
T. N. Meyer; M. J. Kinosz; E. M. Bradac; M. Mbaye; J. T. Burg; M. A. Klingensmith
Optimizing cast blasting efficiency using ANFO with liners
As part of a five research project funded by the National Science Foundation, Peabody Energy studied three experimental cast blasts conducted at the North Antelope Rochelle mine site on July 24,28 and 31 2005. The initial purpose of this research project was to determine the influence that blast initiation sequence have on: NOx production; Face Displacement; Highwall damage; Explosive performance; Vibration emissions; Displacement; Surface swell; and Cast benefit. Two new discoveries on velocity of detonation (VoD) and pressure of detonation (PoD) were made as a result of this research project. Furthermore, a relationship between surface swell velocity and face velocity was also noted. 7 figs., 3 tabs.
Madsen, A.
Tape-cast sensors and method of making
A method of making electrochemical sensors in which an electrolyte material is cast into a tape. Prefabricated electrodes are then partially embedded between two wet layers of the electrolyte tape to form a green sensor, and the green sensor is then heated to sinter the electrolyte tape around the electrodes. The resulting sensors can be used in applications such as, but not limited to, combustion control, environmental monitoring, and explosive detection. A electrochemical sensor formed by the tape-casting method is also disclosed.
Mukundan, Rangachary (Santa Fe, NM); Brosha, Eric L. (Los Alamos, NM); Garzon, Fernando H. (Santa Fe, NM)
Procedure for flaw detection in cast stainless steel
This paper describes a method of ultrasonic flaw detection in cast stainless steel components incorporating the steps of determining the nature of the microstructure of the cast stainless steel at the site of the flaw detection measurements by ultrasonic means independent of the component thickness at the site. Then, choosing from a plurality of flaw detection techniques, one such technique appropriate to the nature of the microstructure as determined is discussed. The detection of flaws by means of the chosen technique is then detailed.
Kupperman, D.S.
Improving the manufacturing yield of investment cast turbine blades through robust design
The manufacturing of turbine blades is often outsourced to investment casting foundries by aerospace companies that design and build jet engines. Aerospace companies have found that casting defects are an important cost ...
Margetts, David (David Lawrence)
CloudCast: Cloud Computing for Short-Term Weather Forecasts
CloudCast provides clients with personalized short-term weather forecasts based on their current location using cloud services
Dilip Kumar Krishnappa; David Irwin; Eric Lyons; Michael Zink
Using ToxCast � to Predict Chemicals Potential for Developmental,
Tens of thousands of chemicals are currently in commerce, and hundreds more are introduced every year. Because there are so many chemicals�and since traditional chemical toxicity tests using animals is expensive and time consuming�only a small fraction of chemicals have been fully assessed for potential risk. In 2007, EPA scientists began working on ToxCast, a research project to identify and prioritize potentially toxic chemicals using rapid, automated tests called in vitro assays. ToxCast is currently examining over 1,000 chemicals from a broad range of sources, including pesticides, industrial and consumer products, food additives and failed drugs that were never released to the market. Recently, EPA scientists published papers describing first generation predictive models (see graphic 1 for process of developing models) using ToxCast data. These models show how the ToxCast concept can be used to predict the potential for certain chemicals to be toxic to embryonic development, male and female reproductive function, and vascular development. The models support continued development of this new approach to chemical safety assessment.
Vascular Development Toxicity; Developmental Toxicity
Cast Alloys for Advanced Ultra Supercritical Steam Turbines
The proposed steam inlet temperature in the Advanced Ultra Supercritical (A-USC) steam turbine is high enough (760 �C) that traditional turbine casing and valve body materials such as ferritic/martensitic steels will not suffice due to temperature limitations of this class of materials. Cast versions of several traditionally wrought Ni-based superalloys were evaluated for use as casing or valve components for the next generation of industrial steam turbines. The full size castings are substantial: 2-5,000 kg each half and on the order of 100 cm thick. Experimental castings were quite a bit smaller, but section size was retained and cooling rate controlled to produce equivalent microstructures. A multi-step homogenization heat treatment was developed to better deploy the alloy constituents. The most successful of these cast alloys in terms of creep strength (Haynes 263, Haynes 282, and Nimonic 105) were subsequently evaluated by characterizing their microstructure as well as their steam oxidation resistance (at 760 and 800 �C).
G. R. Holcomb, P. Wang, P. D. Jablonski, and J. A. Hawk,
Advanced GPU-based ray casting for bricked datasets
Since the 90s, the Direct Volume Rendering shows itself as an efficient tool for the visual analysis of volumetric datasets. There are approaches that allow for the real-time Ray Casting for visualization of the datasets that can be divided into bricks ...
Nikolay Gavrilov; Vadim Turlapov
Azimuthal variation of radiation of seismic energy from cast blasts
As part of a series of seismic experiments designed to improve the understanding of the impact of mining blasts on verifying a Comprehensive Test Ban Treaty, a sixteen station network of three-component seismic sensors were deployed around a large cast shot in the Black Thunder Mine. The seismic stations were placed, where possible, at a range of 2.5 kilometers with a constant inter-station spacing of 22.5 degrees. All of the data were recorded with the seismometers oriented such that the radial component pointed to the middle point of the approximately 2 kilometer long shot. High quality data were recorded at each station. Data were scaled to a range of 2.5 kilometers and the sum of the absolute value of the vertical, radial, and transverse channels computed. These observations were used to construct radiation patterns of the seismic energy propagating from the cast shot. It is obvious that cast shots do not radiate seismic energy isotropically. Most of the vertical motion occurs behind the highwall while radial and transverse components of motion are enhanced in directions parallel to the highwall. These findings have implications for local (0.1 to 15 kilometer range) and possibly for regional (100 to 2,000 kilometer range) seismic observations of cast blasting. Locally, it could be argued that peak particle velocities could be scaled not only by range but also by azimuthal direction from the shot. This result implies that long term planning of pit orientation relative to sensitive structures could mitigate problems with vibration levels from future blasting operations. Regionally, the local radiation pattern may be important in determining the magnitude of large scale cast blasts. Improving the transparency of mining operations to international seismic monitoring systems may be possible with similar considerations.
Pearson, D.C.; Stump, B.W. [Los Alamos National Lab., NM (United States); Martin, R.L. [Thunder Basin Coal Co., Wright, WY (United States)
Rapid tooling for functional prototyping of metal mold processes: Literature review on cast tooling
This report is a literature review on cast tooling with the general focus on AISI H13 tool steel. The review includes processing of both wrought and cast H13 steel along with the accompanying microstructures. Also included is the incorporation of new rapid prototyping technologies, such as Stereolithography and Selective Laser Sintering, into the investment casting of tool steel. The limiting property of using wrought or cast tool steel for die casting is heat checking. Heat checking is addressed in terms of testing procedures, theories regarding the mechanism, and microstructural aspects related to the cracking.
Baldwin, M.D. [Sandia National Labs., Albuquerque, NM (United States); Hochanadel, P.W. [Colorado School of Mines, Golden, CO (United States). Dept. of Metallurgical and Materials Engineering
Office of Scientific and Technical Information (OSTI)
FINAL REPORT FINAL REPORT VOLUME 1 METALLURGICAL EVALUATION OF CAST DUPLEX STAINLESS STEELS AND THEIR WELDMENTS SUBMITTED TO U. S. DEPARTMENT OF ENERGY Award Number - DE-FC36-00 ID13975 OCTOBER 1, 2000 - SEPTEMBER 30, 2005 SONGQING WEN CARL D. LUNDIN GREG BATTEN MATERIALS JOINING GROUP MATERIALS SCIENCE AND ENGINEERING THE UNIVERSITY OF TENNESSEE, KNOXVILLE CARL D. LUNDIN PROFESSOR OF METALLURGY MATERIALS JOINING GROUP MATERIALS SCIENCE AND ENGINEERING THE UNIVERSITY OF TENNESSEE KNOXVILLE 37996-2200 TELEPHONE (865) 974-5310 FAX (865) 974-0880 email@example.com This is Volume 1of 5 of the final report for The Department of Energy Grant # DE-FC36-00 ID13975 entitled "Behavior of Duplex Stainless Steel Castings." ii FOREWARD
Development of Thin Section Zinc Die Casting Technology
A new high fluidity zinc high pressure die casting alloy, termed the HF alloy, was developed during laboratory trials and proven in industrial production. The HF alloy permits castings to be achieved with section thicknesses of 0.3 mm or less. Technology transfer activities were conducted to develop usage of the HF high fluidity alloy. These included production of a brochure and a one-hour webinar on the HF alloy. The brochure was then sent to 1,184 product designers in the Interzinc database. There was excellent reception to this mailing, and from this initial contact 5 technology transfer seminars were conducted for 81 participants from 30 companies across a wide range of business sectors. Many of the successful applications to date involve high quality surface finishes. Design and manufacturing assistance was given for development of selected applications.
Goodwin, Frank [International Lead Zinc Research Org., Inc.] [International Lead Zinc Research Org., Inc.
Publications Dipl.-Ing. Ing. Hana Krsn (ne Spickov)
analýzu VLBI dat. Konferenz des CEDR Center for Earth's Dynamic Research. Trest, Czech Republic, 14 16
Schuh, Harald
In-situ conditioning of a strip casting roll
A strip caster (10) for producing a continuous strip (24) has a tundish (12) for containing a melt (14) and a pair of horizontally disposed water cooled casting rolls (22). The casting rolls are juxtaposed relative to one another for forming a pouring basin (18) for receiving the melt through a teeming tube (16) thereby establishing a meniscus (20) between the rolls for forming a strip (24). The melt is protected from the outside air by a non-oxidizing gas passed through a supply line (28) to a sealing chamber (26). Devices (29) for conditioning the outer peripheral chill surfaces of the casting rolls includes grit blasting nozzles (30A, 30B, 30C, 30D), a collection trough (32) for gathering the grit, a line (34) for recycling the grit to a bag house (36), a feeder (38) and a pressurized distributor (40) for delivering the grit to the nozzles. The conditioning nozzles remove dirt, metal oxides and surface imperfections providing a clean surface readily wetted by the melt.
Williams, R.S.; Campbell, S.L.
Williams, Robert S. (Fairfield, OH); Campbell, Steven L. (Middletown, OH)
Commercialization effort in support of electroslag-casting technology
This report summarizes the results of an effort to revive interest in the electroslag casting (ESC) of components in the United States. The ESC process is an extension of a well established electroslag-remelting (ESR) process. Both processes use the electrode of a material that is continuously melted and cast in a water-cooled copper mold. For simple shapes, the mold can be movable, allowing the continuous casting of long lengths. In an effort to revive US industries` interest in ESC, the following approaches were taken: (1) US industries with prior experience in ESC or currently operating an ESR unit were contacted, followed up with telephone conversation, and/or sent copies of prior published reports on the topic, and, in some cases, personal visits were made; (2) with two companies, a potential interest in ESC was worked out by initially conducting ESR; and (3) to further strengthen the industrial interest, the newly developed iron-aluminide alloy, FA-129, was chosen as the material of choice for this study. The two industrial companies that worked with ORNL were Special Metals Corporation (New Hartford, New York) and Precision Rolled Products, Inc. (PRP) [Florham Park, New Jersey]. Even with its advantages, a survey of the industry indicated that ESC technology has a very limited chance of advancement in the United States. However, the processing of rounds and slabs by the ESR process is a well established commercial technology and will continue to expand. 16 figs, 3 tabs, 12 refs.
Sikka, V.K.
Data Package for Secondary Waste Form Down-Selection�Cast Stone
Available literature on Cast Stone and Saltstone was reviewed with an emphasis on determining how Cast Stone and related grout waste forms performed in relationship to various criteria that will be used to decide whether a specific type of waste form meets acceptance criteria for disposal in the Integrated Disposal Facility (IDF) at Hanford. After the critical review of the Cast Stone/Saltstone literature, we conclude that Cast Stone is a good candidate waste form for further consideration. Cast stone meets the target IDF acceptance criteria for compressive strength, no free liquids, TCLP leachate are below the UTS permissible concentrations and leach rates for Na and Tc-99 are suiteably low. The cost of starting ingredients and equipment necessary to generate Cast Stone waste forms with secondary waste streams are low and the Cast Stone dry blend formulation can be tailored to accommodate variations in liquid waste stream compositions. The database for Cast Stone short-term performance is quite extensive compared to the other three candidate waste solidification processes. The solidification of liquid wastes in Cast Stone is a mature process in comparison to the other three candidates. Successful production of Cast Stone or Saltstone has been demonstrated from lab-scale monoliths with volumes of cm3 through m3 sized blocks to 210-liter sized drums all the way to the large pours into vaults at Savannah River. To date over 9 million gallons of low activity liquid waste has been solidified and disposed in concrete vaults at Savannah River.
Serne, R. Jeffrey; Westsik, Joseph H.
Gasoline and Diesel Fuel Update (EIA)
9) 9) The Na tional En ergy Mod el ing Sys tem: An Over view 2009 October 2009 En ergy In for ma tion Ad min is tra tion Of fice of In te grated Anal y sis and Fore cast ing U.S. De part ment of En ergy Wash ing ton, DC 20585 This re port was pre pared by the En ergy In for ma tion Ad min is tra tion, the in de pend ent sta tis ti cal and an a lyt i cal agency within the U.S. De part ment of En ergy. The in for ma tion con tained herein should be at trib uted to the En ergy In for ma tion Ad min is tra tion and should not be con strued as ad vo cat ing or re flect ing any pol icy po si tion of the De part ment of En ergy or any other or ga ni za tion. This pub li ca tion is on the WEB at: www.eia.doe.gov/oiaf/aeo/over view/ The Na tional En ergy Mod el ing Sys tem: An Over view 2009 pro vides a sum mary de scrip tion of the Na tional En ergy
Expandable pattern casting research. Phase 2, Final report, October 1, 1990--March 31, 1993
The Expandable Pattern Casting (EPC) Process is a developing foundry technology that allows designers the opportunity to consolidate parts, reduce machining, and minimize assembly operations. An air gauging system was developed for measuring foam patterns; exact shrinkage depended on type and density of the foam. Compaction studies showed that maximum sand densities in cavities and under overhangs are achieved with vibrational amplitudes 0.001--0.004 in., and that sand moved most freely within a few inches of the top free surface. Key to complete mold filling while minimizing casting defects lies in removing the foam decomposition products. The most precise iron castings were made by EPC in four commercial EPC foundries, with attention paid to molding and compaction. EP cast 60-45-12 ductile iron had yield strengths, ultimate strengths, and elastic modulus similar to conventionally cast ductile iron cast from the same ladle.
Not Available
Cast Metals Coalition Technology Transfer and Program Management Final Report
The Cast Metals Coalition (CMC) partnership program was funded to ensure that the results of the Department of Energy's (DOE) metalcasting research and development (R&D) projects are successfully deployed into industry. Specifically, the CMC program coordinated the transfer and deployment of energy saving technologies and process improvements developed under separately funded DOE programs and projects into industry. The transition of these technologies and process improvements is a critical step in the path to realizing actual energy savings. At full deployment, DOE funded metalcasting R&D results are projected to save 55% of the energy used by the industry in 1998. This closely aligns with DOE's current goal of driving a 25% reduction in industrial energy intensity by 2017. In addition to benefiting DOE, these energy savings provide metalcasters with a significant economic advantage. Deployment of already completed R&D project results and those still underway is estimated to return over 500% of the original DOE and industry investment. Energy savings estimates through December 2008 from the Energy-Saving Melting and Revert Reduction Technology (E-SMARRT) portfolio of projects alone are 12 x 1012 BTUs, with a projection of over 50 x 1012 BTUs ten years after program completion. These energy savings and process improvements have been made possible through the unique collaborative structure of the CMC partnership. The CMC team consists of DOE's Office of Industrial Technology, the three leading metalcasting technical societies in the U.S: the American Foundry Society; the North American Die Casting Association; and the Steel Founders Society of America; and the Advanced Technology Institute (ATI), a recognized leader in distributed technology management. CMC provides collaborative leadership to a complex industry composed of approximately 2,100 companies, 80% of which employ less than 100 people, and only 4% of which employ more than 250 people. Without collaboration, new technologies enabling energy efficiencies and environment-friendly improvements are slow to develop, and have trouble obtaining a broad application. The CMC team was able to effectively and efficiently transfer the results of DOE's metalcasting R&D projects to industry by utilizing and delivering the numerous communication vehicles identified in the proposal. The three metalcasting technical associations achieved significant technology transition results under this program. In addition to reaching over 23,000 people per year through Modern Casting and 28,000 through Engineered Casting Solutions, AFS had 84 national publications and reached over 1,200 people annually through Cast Metals Institute (CMI) education courses. NADCA's education department reached over 1,000 people each year through their courses, in addition to reaching over 6,000 people annually through Die Casting Engineer, and publishing 58 papers. The SFSA also published 99 research papers and reached over 1,000 people annually through their member newsletters. In addition to these communication vehicles, the CMC team conducted numerous technical committee meetings, project reviews, and onsite visits. All of these efforts to distribute the latest metalcasting technologies contributed to the successful deployment of DOE's R&D projects into industry. The DOE/CMC partnership demonstrated significant success in the identification and review of relevant and easy-to-implement metalcasting energy-saving processes and technologies so that the results are quickly implemented and become general practice. The results achieved in this program demonstrate that sustained technology transfer efforts are a critical step in the deployment of R&D projects to industry.
Gwyn, Mike
Die casting research. Annual progress report, June 29, 1994--June 30, 1995
Cr carbide and other CVD coatings were evaluated for improving wear resistance of Al and Zn die casting dies; die cavity instrumentation was also studied.
Brevick, J.; Mobley, C.; Shivpuri, R.; Goodwin, F.
October 28-29, 2013 Web Cast Info | U.S. DOE Office of Science...
October 28-29, 2013 Web Cast Info Biological and Environmental Research Advisory Committee (BERAC) BERAC Home Meetings BERAC Minutes BERAC Minutes Archive Members ChargesReports...
Moving towards Sustainability: Improving Material Flows in the Iron Casting Industry.
??ustainable engineering solutions were developed to improve the sustainability of the iron casting process. These engineering solutions aimed to modify the material and energy flow� (more)
Huang, He
Effect of Electromagnetic Stirring on the Structure of Cast Al-4.5%Cu ...
Production of High-Strength P/M Disc Alloys by "Superclean" Cast ...
been produced by conventional powder metallurgy techniques as well as. Electron Beam Cold Hearth Refining (EBCHR), which is a cast/wrought method of.
Assessing Cast Alloys for Use in Advanced Ultra-supercritical Steam ...
... of these alloys were examined via SEM; phase identification and chemistry are being ... Phase Stability of Cast and Wrought IN 740 at Ultra Supercritical Boiler�...
Solidification Heat Transfer Analysis of AZ91D Cast Strip by Using a ...
The heat transfer coefficient between the molten magnesium ally and copper roll is important to cast magnesium strip. In the present study investigate the heat�...
ICME Modeling of a Super Vacuum Die Cast (SVDC) AZ91 ...
... of a super vacuum die cast (SVDC) AZ91 automotive shock tower component. .... PI-7: A Three-dimensional Lattice Boltzmann Model for Columnar Dendrite�...
Casting and heat treatment of water jet entry edge made from ...
The number, location and shape of risers and chillers were determined using Nova casting simulation software. ASTM A757 C1Q steel was used for actual�...
Thermal Test of Cast Iron Cooling Stave Produced by Lost Foam ...
The producing of cooling stave using lost foam casting process has the advantages of .... Numerical simulation of microwave absorption of regenerative heat�...
Costs Models in Design and Manufacturing of Sand Casting Products
In the early phases of the product life cycle, the costs controls became a major decision tool in the competitiveness of the companies due to the world competition. After defining the problems related to this control difficulties, we will present an approach using a concept of cost entity related to the design and realization activities of the product. We will try to apply this approach to the fields of the sand casting foundry. This work will highlight the enterprise modelling difficulties (limits of a global cost modelling) and some specifics limitations of the tool used for this development. Finally we will discuss on the limits of a generic approach.
Perry, Nicolas; Bernard, Alain
Nicolas Perry; Magali Mauchand; Alain Bernard
Filler metal alloy for welding cast nickel aluminide alloys
A filler metal alloy used as a filler for welding east nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and east in copper chill molds.
Santella, Michael L. (Knoxville, TN); Sikka, Vinod K. (Oak Ridge, TN)
A composition is given for slip casting tungsten metal. The composition consists essentially of tungsten metal with an average particle size of 0.9 micron, an organic vehicle such as methyl chloroform, o-xylene, n-butyl acetate, isobutyl acetate, and 1, 1, 2, 2-tetrachlorethane, and a suspending agent such as ethyl cellulose, with the approximate ratio of said vehicle to the tungsten metal being 12 cc of a solution containing from 5 to about 20 grams of said ethyl cellulose in 400 cc of said organic vehicle per 100 grams of metal. (AEC)
Stoddard, S.D.; Nuckolls, D.E.; Cowan, R.E.
The thermal cycling, irradiation behavior, and fabrication characteristics of U are strongly dependent upon grain size; a smaller grain size yields the better properties. Grain refinement of cast U may be accomplished either by hot working in the high alpha temperature range or by heat treatment; refinement by the latter method was the object of this investigation. The variables studied were time, temperature, specimen size, multiple quenching, and alphaannealing after quenching. The results of the investigation have led to the following conclusions, within the scope of the experimental conditions. The grain size of cast U may be appreciably refined by beta-quenching. Time and temperature in the beta phase are not significant in determining the final alpha grain size. Multiple beta-quenches (two to four times) produce better grain size refinement than a single quench. Alpha-annealing after beta-quenching causes recrystallization, but does not greatly affect the grain size. Gamma-quenching is not recommended as a practical heat treatment. (auth)
Powell, G.W.; Klein, J.L.; Krashes, D.
Energy Saving Melting and Revert Reduction (E-SMARRT): Precision Casting of Steel
This project addresses improvements in metal casting processes by reducing scrap and reducing the cost of production, due to scrap reduction from investment casting and yield improvement offered by lost foam casting as compared to no-bake or green sand molding. The objectives for the investment casting portion of the subtask are to improve knowledge of fracture toughness of mold shells and the sources of strength limiting flaws and to understand the effects of wax reclamation procedures on wax properties. Applying 'clean steel' approaches to pouring technology and cleanliness in investment casting of steel are anticipated to improve incoming materials inspection procedures as they affect the microstructure and toughness of the shell. This project focused on two areas of study in the production of steel castings to reduce scrap and save energy: (1) Reducing the amount of shell cracking in investment cast steel production; (2) Investigate the potential of lost foam steel casting The basic findings regarding investment casting shell cracking were: (1) In the case of post pouring cracking, this could be related to phase changes in silica upon cooling and could be delayed by pouring arrangement strategies that maintained the shell surface at temperature for longer time. Employing this delay resulted in less adherent oxidation of castings since the casting was cooler at the time o fair exposure. (2) A model for heat transfer through water saturated shell materials under steam pressure was developed. (3) Initial modeling result of autoclave de-waxing indicated the higher pressure and temperature in the autoclave would impose a steeper temperature gradient on the wax pattern, causing some melt flow prior to bulk expansion and decreasing the stress on the green shell. Basic findings regarding lost foam casting of steel at atmospheric pressure: (1) EPS foam generally decomposes by the collapse mode in steel casting. (2) There is an accumulation of carbon pick-up at the end of the casting opposite the gate. (3) It is recommended that lost foam castings in steel be gated for a quiescent fill in an empty cavity mold to prevent foam occlusion defects from the collapse mode. The energy benefit is primarily in yield savings and lower casting weight per function due to elimination of draft and parting lines for the larger lost foam castings. For the smaller investment casting, scrap losses due to shell cracking will be reduced. Both of these effects will reduce the metal melted per good ton of castings. There will also be less machine stock required per casting which is a yield savings and a small additional energy savings in machining. Downstream savings will come from heavy truck and railroad applications. Application of these processes to heavy truck castings will lighten the heavy truck fleet by about ten pounds per truck. Using ten years to achieve full penetration of the truck fleet at linear rate this will result in a fuel savings of 131 trillion BTU over ten years.
Dr. Von L. Richards
CANDIE: A New Version of the DieCAST Ocean Circulation Model
The development and verification of a new version of the DieCAST ocean circulation model to be referred to as CANDIE (Canadian Diecast) are considered. Both CANDIE and DieCAST have many features in common with the well-known Modular Ocean Model (...
Jinyu Sheng; Daniel G. Wright; Richard J. Greatbatch; David E. Dietrich
Passive Time Coincidence Measurements with Assemblies of HEU and DU Castings
Five highly enriched (93.2 wt% 235U) uranium (HEU) and three depleted (0.2 wt% 235U) uranium (DU) castings were available for passive time coincidence measurements with two arrays of eight total liquid scintillation detectors and two arrays of 32 total moderated 3He detectors. In addition to measurements with each type of casting, measurements were also performed with both types of castings intermingled. The spontaneous fission rate for the casting is primarily due to the presence of 238U. Thus, the DU castings have ~15 times more spontaneous fission that the HEU castings with very little addition in multiplication with each addition of a DU casting. The characteristic time behavior of the fission chain multiplication process is determined by the 235U. The presence of the DU castings in these assemblies has three physical effects: provision of an additional source of neutrons to initiate fission chains in the HEU, reflection of neutrons back into the HEU, and shielding of the detectors from fission chain neutrons and gammas. The effects are investigated within the context of the time coincidence distributions using the signal-triggered multiplets and Feynman variances.
McConchie, Seth M [ORNL; Hausladen, Paul [ORNL; Mihalczo, John T [ORNL
Boundary element stress analysis for copper-based dies in pressure die casting
It has recently been demonstrated that, for pressure die casting, high rates of heat extraction are possible with the use copper-alloyed dies suitably protected with a thermally sprayed steel layer. The structural integrity of dies of this type is paramount ... Keywords: Boundary elements, Casting, Elastostatics, Sprayed dies
M. T. Alonso Rasgado; K. Davey; L. D. Clark; S. Hinduja
Modelling the environmental impact of an aluminium pressure die casting plant and options for control
This study describes a model (MIKADO) to analyse options to reduce the environmental impact of aluminium die casting. This model will take a company perspective, so that it can be used as a decision-support tool for the environmental management of a ... Keywords: Aluminium die casting plant, Environmental decision-support tool, Environmental impact assessment, Integrated Assessment Model, Modelling
Belmira Neto; Carolien Kroeze; Leen Hordijk; Carlos Costa
Cast stone technology is being evaluated for potential application in the treatment and immobilization of Hanford low-activity waste. The purpose of this document is to provide background information on cast stone technology. The information provided in the report is mainly based on a pre-conceptual design completed in 2003.
Clean Cast Steel Technology: Effect of Micro-porosity on Tensile and Charpy Properties of Four Cast Steels
The effect of these large shrink cavities on mechanical properties could be easily calculated using well established engineering formulas. Over the years, increases in computational and metallurgical resources have allowed the modeler to improve accuracy and increase the complexity of numerical predictors. An accurate prediction of micro-porosity, not observable using conventional radiographic techniques, and an engineering understanding of the effect on mechanical properties would give a designer confidence in using a more efficient casting design and a lower safety factor. This will give castings an additional design advantage. The goal of this project is to provide current and future modelers/designers with a tensile and Charpy property dataset for validation of micro-porosity predictors. The response of ultimate strength, elongation, and reduction in area to micro-porosity was very similar in all four alloys. Ultimate strength was largely unaffected by tensile fracture surface porosity until values of about 25% were reached and decreased linearly with increasing values. Elongation and reduction in area decreased sharply after less than 5% fracture surface porosity. Niyama values of about 0.7 were produced sound material and acceptable tensile properties. Ultrasonic velocities of 0.233 in/usec and higher produced acceptable tensile properties. Metallographic examination revealed a ratio of 4-6 to 1 in fracture surface porosity to metallographic porosity. Charpy impact properties were largely unaffected by the microporosity concentrations examined in this study and did not correlate to either Niyama values, fracture surface porosity, or metallographic porosity.
Griffin, John, A.; Bates, Charles, E.
Rethinking the physical layer of data center networks of the next decade: using optics to enable efficient *-cast connectivity
Not only do big data applications impose heavy bandwidth demands, they also have diverse communication patterns denoted as *-cast) that mix together unicast, multicast, incast, and all-to-all-cast. Effectively supporting such traffic demands remains ... Keywords: all-to-all-cast, data center networks, hybrid networks, incast, multicast, optical networks, photonics, unicast
Howard Wang, Yiting Xia, Keren Bergman, T.S. Eugene Ng, Sambit Sahu, Kunwadee Sripanidkulchai
The CERN Axion Solar Telescope (CAST): Status and Prospects
The CAST experiment is being mounted at CERN. It will make use of a decommissioned LHC test magnet to look for solar axions through its conversion into Photons inside the magnetic field. The magnet has a field of 9.6 Tesla and length of 10 m and is installed in a platform which allows to move it+ or - 8 degrees vertically and+ or - 10 to the 11th power horizontally. According to these numbers we expect a sensitivity in axion-photon coupling gaT"~ ,~< 5 10 -11 GeV -1 for ma~< 0.02 eV, and with a gas filled tube ga~~< 10 -l GeV -a for ma~< 1 eV.
Irastorza, I. G. (Universidad de Zaragoza); Andriamonje, S (DAPNIA, Centre d'Etudes de Saclay); Arik, E (Bogazici Universitesi); Autiero, D (European Organization for Nuclear Research); Avignone, F T. (South Carolina, Univ Of); Barth, K (European Organization for Nuclear Research); Brauninger, H (Max-Planck-Institut fur Extraterrestrische Physik); Brodzinski, Ronald L. (BATTELLE (PACIFIC NW LAB)); Carmona, J. M. (Universidad de Zaragoza); Cebrian, S (Unknown); Cetin, S (Bogazici Universitesi); Collar, J I. (Chicago, University Of); Creswick, R (South Carolina, Univ Of); De Oliveira, R (European Organization for Nuclear Research); Delbart, A (Centre d'Etudes de Saclay); Di Lella, L (European Organization for Nuclear Research); Eleftheriadis, Ch (Aristotle University of Thessaloniki); Fanourakis, G (National Research Center for Physical Sciences, Demokritos, Greece); Farach, H A. (South Carolina, Univ Of); Fischer, H (Albert-Ludwigs-Universitat Freiburg); Formenti, F (European Org for Nuclear Research); Geralis, Th. (National Research Center for Physical Sciences, Demokritos, Greece); Giomataris, I (Centre d'Etudes de Saclay, Gif-Sur-Yvette, France); Gninenko, S. N. (Institue for Nuclear Research, Moscow, Russia); Goloubev, N (Institute for Nuclear Research); Hartman, R (Max-Planck-Institut fur Extraterrestrische Physik); Hasinoff, M (British Columbia,University of); Hoffmann, D (Technische Universitat Darmstadt); Jacoby, J (Technische Universitat Darmstadt); Kang, D (Albert-Ludwigs-Universitat Freiburg); Konigsmann, K (Albert-Ludwigs-Universitat Freiburg); Kotthaus, R (Max-Planck-Institut fur Physik, Muenchen, Germany); Krcmar, M (Ruder Boskovic Institute); Kuster, M (Max-Planck-Institute fur Extraterrestrische Physik); Lakic, B (Ruder Boskovic Institute, Zagreb, Croatia); Liolios, A (Universidade de Lisboa); Ljubicic, A (Ruder Boskovic Institute, Zagreb, Croatia); Lutz, G (Max-Planck-Institut fur Physik, Muenchen, Germany); Luzon, G (Universidad de Zaragoza); Miley, Harr
Clean Ferrous Casting Technology Research. Annual report, September 29, 1993--September 28, 1994
This annual report covers work performed in the first year of research on Clean Ferrous Casting Technology Research. During this year the causes of penetration of cast iron in sand molds were defined and a program which predicts the occurrence of penetration was written and verified in commercial foundries. Calculations were made to size a reaction chamber to remove inclusions from liquid steel using electromagnetic force and the chamber was built. Finally, significant progress was made in establishing pouring practices which avoid re-oxidation of steel during pouring application of revised pouring practices have led to reduced inclusion levels in commercially poured steel castings.
Stefanescu, D.M.; Lane, A.M.; Giese, S.R.; Pattabhi, R.; El-Kaddah, N.H.; Griffin, J.; Bates, C.E.; Piwonka, T.S.
The ultimate objective of this work was to eliminate approximately 30% of the machining performed in typical automotive engine and transmission plants by using thread forming fasteners in as-cast holes of aluminum and magnesium cast components. The primary issues at the source of engineers�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?¢�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�? reluctance to implementing thread forming fasteners in lightweight castings are: * Little proof of consistency of clamp load vs. input torque in either aluminum or magnesium castings. * No known data to understand the effect on consistency of clamp load as casting dies wear. The clamp load consistency concern is founded in the fact that a portion of the input torque used to create clamp load is also used to create threads. The torque used for thread forming may not be consistent due to variations in casting material, hole size and shape due to tooling wear and process variation (thermal and mechanical). There is little data available to understand the magnitude of this concern or to form the basis of potential solutions if the range of clamp load variation is very high (> +/- 30%). The range of variation that can be expected in as-cast hole size and shape over the full life cycle of a high pressure die casting die was established in previous work completed by Pacific Northwest National Laboratory, (PNNL). This established range of variation was captured in a set of 12 cast bosses by designing core pins at the size and draft angles identified in the sited previous work. The cast bosses were cut into �?�?�?�?�?�?�?�?�?�?�?�?�?�?�?¢�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?nuts�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?¢�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�?�? that could be used in the Ford Fastener Laboratory test-cell to measure clamp load when a thread forming fastener was driven into a cast nut. There were two sets of experiments run. First, a series of cast aluminum nuts were made reflecting the range of shape and size variations to be expected over the life cycle of a die casting die. Taptite thread forming fasteners, (a widely used thread forming fastener suitable for aluminum applications), were driven into the various cored, as-cast nuts at a constant input torque and resulting clamp loads were recorded continuously. The clamp load data was used to determine the range of clamp loads to be expected. The bolts were driven to failure. The clamp load corresponding to the target input of 18.5 Nm was recorded for each fastener. In a like fashion, a second set of experiments were run with cast magnesium nuts and ALtracs thread forming fasteners, (a widely used thread forming fastener suitable for magnesium applications). Again all clamp loads were recorded and analyzed similarly to the Taptites in aluminum cast nuts. Results from previous work performed on the same test cell for a Battelle project using standard M8 bolts into standard M8 nuts were included as a comparator for a standard bolt and nut application. The results for the thread forming fasteners in aluminum cast holes were well within industry expectations of +/- 30% for out of the box and robustness range te
Cleaver, Ryan J.; Cleaver, Todd H.; Talbott, Richard
Energy and Security in Northeast Asia: Supply and Demand, Conflict and
of China's energy policy. The government attaches greatthis way, energy de- mand together with government policiesgovernment fore- casts, policies regarding fuel choice, and how energy
Fesharaki, Fereidun; Banaszak, Sarah; WU, Kang; Valencia, Mark J.; Dorian, James P.
Simulation of A356 Semi-Solid Die-Casting Using Power-Law Model
Investment Casting of Titanium Alloys with CaO Crucible and ...
Feb 1, 2001 ... Investment Casting of Titanium Alloys with CaO Crucible and CaZrO3 Mold by S. K. Kim, T. K. Kim, M. G. Kim, T. W. Hong and J. Y. Kim�...
P1-15: Gating System Optimisation Design Study of a Cast ...
Different designs of the gating and risering systems for the cast automobile ... P1- 04: 3D Microstructural Characterization of Uranium Oxide as a Surrogate Nuclear ... P2-27: Characterization of Carbonate Rocks through X-ray Microtomography.
Program on Technology Innovation: Recent Developments in the Inspection of Cast Austenitic Stainless Steel Components
Cast austenitic stainless steel (CASS) materials are prevalent in many safety-related nuclear power plant components, including the primary coolant piping system in pressurized water reactors (PWRs). CASS components are also currently being designed for new power plant construction. The long-term performance of this material, however, is not fully understood.The volumetric examination of cast stainless steel piping is required, but no current reliable nondestructive evaluation (NDE) ...
Pulsed Neutron Measurments With A DT Neutron Generator for an Annular HEU Uranium Metal Casting
Measurements were performed with a single annular, stainless-steel-canned casting of uranium (93.17 wt% 235U) metal ( ~18 kg) to provide data to verify calculational methods for criticality safety. The measurements used a small portable DT generator with an embedded alpha detector to time and directionally tag the neutrons from the generator. The center of the time and directional tagged neutron beam was perpendicular to the axis of the casting. The radiation detectors were 1x1x6 in plastic scintillators encased in 0.635-cm-thick lead shields that were sensitive to neutrons above 1 MeV in energy. The detector lead shields were adjacent to the casting and the target spot of the generator was about 3.8 cm from the casting at the vertical center. The time distribution of the fission induced radiation was measured with respect to the source event by a fast (1GHz) processor. The measurements described in this paper also include time correlation measurements with a time tagged spontaneously fissioning 252Cf neutron source, both on the axis and on the surface of the casting. Measurements with both types of sources are compared. Measurements with the DT generator closely coupled with the HEU provide no more additional information than those with the Cf source closely coupled with the HEU and are complicated by the time and directionally tagged neutrons from the generator scattering between the walls and floor of the measurements room and the casting while still above detection thresholds.
Laboratory testing and technical evaluation activities on Containerized Cast Stone (CCS) were conducted under the Scope of Work (SOW) contained in CH2M HILL Hanford Group, Inc. (CHG) Contract No. 18548 (CHG 2003a). This report presents the results of testing and demonstration activities discussed in SOW Section 3.1, Task I--''Process Development Testing'', and described in greater detail in the ''Containerized Grout--Phase I Testing and Demonstration Plan'' (CHG, 2003b). CHG (2003b) divided the CCS testing and evaluation activities into six categories, as follows: (1) A short set of tests with simulant to select a preferred dry reagent formulation (DRF), determine allowable liquid addition levels, and confirm the Part 2 test matrix. (2) Waste form performance testing on cast stone made from the preferred DRF and a backup DRF, as selected in Part I, and using low activity waste (LAW) simulant. (3) Waste form performance testing on cast stone made from the preferred DRF using radioactive LAW. (4) Waste form validation testing on a selected nominal cast stone formulation using the preferred DRF and LAW simulant. (5) Engineering evaluations of explosive/toxic gas evolution, including hydrogen, from the cast stone product. (6) Technetium ''getter'' testing with cast stone made with LAW simulant and with radioactive LAW. In addition, nitrate leaching observations were drawn from nitrate leachability data obtained in the course of the Parts 2 and 3 waste form performance testing. The nitrate leachability index results are presented along with other data from the applicable activity categories.
Energy and Technolgy Assessment of Zinc and Magnesium Casting Plants, Technical Report Close-out, August 25,2006
Twin City Die Castings Company of Minneapolis, Minnesota, Twin City Die Castings Company was awarded project No. DE-FG36-05GO15097 to perform plant wide assessments of ten (10) die casting facilities that produce zinc and magnesium alloy castings in order to determine improvements and potential cost savings in energy use. Mr. Heider filled the role of team leader for the project and utilized the North American Die Casting Association (NADCA) to conduct audits at team participant plants so as to hold findings specific to each plant proprietary. The intended benefits of the project were to improve energy use through higher operational and process efficiency for the plants assessed. An improvement in energy efficiency of 5 � 15% was targeted. The primary objectives of the project was to: 1) Expand an energy and technology tool developed by the NADCA under a previous DOE project titled, �Energy and Technology Assessment for Die Casting Plants� for assessing aluminum die casting plants to be more specifically applicable to zinc and magnesium die casting facilities. 2) Conduct ten (10) assessments of zinc and magnesium die casting plants, within eight (8) companies, utilizing the assessment tool to identify, evaluate and recommend opportunities to enhance energy efficiency, minimize waste, and improve productivity. 3) Transfer the assessment tool to the die casting industry at large.
Twin City Die Castings Company; Tom Heider; North American Die Castings Association
Simulation of Distortion and Residual Stress Development During Heat Treatment of Steel Castings
Heat treatment and associated processing, such as quenching, are critical during high strength steel casting production. These processes must be managed closely to prevent thermal and residual stresses that may result in distortion, cracking (particularly after machining), re-work, and weld repair. The risk of casting distortion limits aggressive quenching that can be beneficial to the process and yield an improved outcome. As a result of these distortions, adjustments must be made to the casting or pattern design, or tie bars must be added. Straightening castings after heat treatments can be both time-consuming and expensive. Residual stresses may reduce a casting�?�?�?¢�?�?�?�?�?�?�?�?s overall service performance, possibly resulting in catastrophic failure. Stress relieving may help, but expends additional energy in the process. Casting software is very limited in predicting distortions during heat treatment, so corrective measures most often involve a tedious trial-and-error procedure. An extensive review of existing heat treatment residual stress and distortion modeling revealed that it is vital to predict the phase transformations and microstructure of the steel along with the thermal stress development during heat treatment. After reviewing the state-of-the-art in heat treatment residual stress and distortion modeling, an existing commercial code was selected because of its advanced capabilities in predicting phase transformations, the evolving microstructure and related properties along with thermal stress development during heat treatment. However, this software was developed for small parts created from forgings or machined stock, and not for steel castings. Therefore, its predictive capabilities for heat treatment of steel castings were investigated. Available experimental steel casting heat treatment data was determined to be of insufficient detail and breadth, and so new heat treatment experiments were designed and performed, casting and heat treating modified versions of the Navy-C ring (a classical test shape for heat treatment experiments) for several carbon and low alloy steels in order to generate data necessary to validate the code. The predicted distortions were in reasonable agreement with the experimentally measured values. However, the final distortions in the castings were small, making it difficult to determine how accurate the predictions truly are. It is recommended that further validation of the software be performed with the aid of additional experiments with large production steel castings that experience significant heat treatment distortions. It is apparent from this research that the mechanical properties of the bonded sand used for cores and sand molds are key in producing accurate stress simulation results. Because of this, experiments were performed to determine the temperature-dependent elastic modulus of a resin-bonded sand commonly utilized in the steel casting industry. The elastic modulus was seen to vary significantly with heating and cooling rates. Also, the retained room temperature elastic modulus after heating was seen to degrade significantly when the sand was heated above 125�?�?�?�?�?�?�?°C. The elastic modulus curves developed in this work can readily be utilized in casting simulation software. Additional experiments with higher heating rates are recommended to determine the behavior of the elastic modulus in the sand close to the mold-metal interface. The commercial heat treatment residual stress and distortion code, once fully validated, is expected to result in an estimated energy savings of 2.15 trillion BTU�?�?�?¢�?�?�?�?�?�?�?�?s/year. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology.
Christoph Beckermann; Kent Carlson
Simulation of Dimensional Changes and Hot Tears During Solidification of Steel Castings
During solidification, contractions or distortions of the steel, known as �?�?�?¢�?�?�?�?�?�?�?�?dimensional changes,�?�?�?¢�?�?�?�?�?�?�? can cause the final product to vary significantly from the original pattern. Cracks in the casting that form during the late stages of solidification, called �?�?�?¢�?�?�?�?�?�?�?�?hot tears,�?�?�?¢�?�?�?�?�?�?�? occur when contractions can no longer be accommodated by residual liquid metal flow or solid metal displacement. Dimensional changes and hot tears are major problems in the steel casting industry. These occurrences are difficult to anticipate and correct using traditional foundry engineering methods. While dimensional changes are accommodated using pattern allowances, the desired dimensions are often inaccurate. Castings that form hot tears must then be scrapped or weld repaired, expending unnecessary energy. Correcting either of these problems requires a tedious trial-and-error process that may not necessarily yield accurate results. A model that predicts hot tears and dimensional changes during steel casting solidification has been successfully developed and implemented in commercial casting and stress analysis software. This model is based on a visco-plastic constitutive model with damage, where the damage begins to form when liquid feed metal is cut off to a solidifying region. The hot tear prediction is a locater for hot tear initiation sites, and not a full tear prediction: casting regions with relatively high damage values indicate where a casting is more likely to tear. In addition to model development, experimental castings were designed and produced, to provide both hot tear and dimensional change data during casting solidification and cooling. In both experimental castings and industrial production castings, regions of high damage were seen to correlate reasonably well with hot tear locations. Reasonable prediction of dimensional changes was also seen. The predictive capability of the model will improve with the development of more accurate high-temperature mechanical properties. The hot tear/dimensional change model provides the steel casting industry with a tool that will result in a reduction of scrapped castings and re-work/repair due to dimensional changes or hot tears, and also an increase in casting yield due to a reduction in the use of padding and improved placement of risers, leading to better riser efficiency. This new technology is expected to result in an estimated energy savings of 2.15 trillion BTU�?�?�?¢�?�?�?�?�?�?�?�?s/year. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology.
Prompt Neutron Time Decay in Single HEU and DU Metal Annular Storage Castings
Previous measurements of highly enriched uranium (HEU) storage castings performed by Oak Ridge National Laboratory (ORNL) at the Y-12 National Security Complex showed a prompt neutron time decay that is not exponential. These measurements showed that multiple time constants originating from multiplication, time-of-flight, scattering in the assembly and room return could be associated with this prompt neutron decay. In this work, the contribution not associated with neutron multiplication was investigated via measurements with a depleted uranium (DU) casting. The measurements at ORNL used an annular (5.0-in OD, 3.5-in ID, 6.0-in H) DU casting with a time-tagged 252Cf source, centered vertically on the axis, and four closely coupled 1 1 6-in.-long plastic scintillators with -in.- thick lead shielding adjacent to the outer surface of the casting. This setup was identical to the configuration used in the previously performed measurements with HEU castings at Y-12. The time correlation between fission events and detections in the plastic scintillators was measured, as well as the time distribution of coincidences between multiple detectors within a 512-ns time window. The measurement results were then compared to MCNP-PoliMi calculations and the previous HEU measurements. Time constants from decay fits to the HEU and DU data were compared to characterize the contributions resulting from multiplication, time-of-flight, and scattering.
Pena, Kirsten E [ORNL; McConchie, Seth M [ORNL; Mihalczo, John T [ORNL
Casting Apparatus Including A Gas Driven Molten Metal Injector And Method
The casting apparatus (50) includes a holding vessel (10) for containing a supply of molten metal (12) and a casting mold (52) located above the holding vessel (10) and having a casting cavity (54). A molten metal injector (14) extends into the holding vessel (10) and is at least partially immersed in the molten metal (12) in the holding vessel (10). The molten metal injector (14) is in fluid communication with the casting cavity (54). The molten metal injector (14) has an injector body (16) defining an inlet opening (24) for receiving molten metal into the injector body (16). A gas pressurization source (38) is in fluid communication with the injector body (16) for cyclically pressurizing the injector body (16) and inducing molten metal to flow from the injector body (16) to the casting cavity (54). An inlet valve (42) is located in the inlet opening (24) in the injector body (16) for filling molten metal into the injector body (16). The inlet valve (42) is configured to prevent outflow of molten metal from the injector body (16) during pressurization and permit inflow of molten metal into the injector body (16) after pressurization. The inlet valve (42) has an inlet valve actuator (44) located above the surface of the supply of molten metal (12) and is operatively connected to the inlet valve (42) for operating the inlet valve (42) between open and closed positions.
Meyer, Thomas N. (Murrysville, PA)
Improving the Efficiency of Die Casting Machine Hydraulic Systems with the Retrofit of Adjustable Frequency Drives
Die casting is a common method of light metal processing which is used to produce accurately dimensioned, sharply defined metal parts. Most die casting machines in use today utilize a complex hydraulic system to perform the necessary work required for the process. The pressure and flow rate demands on the hydraulic system vary significantly throughout the cycle. Many older systems are greatly oversized so that they are able to meet the peak hydraulic demand at any point. These systems operate inefficiently because there is typically no way to limit the hydraulic capacity during periods of low demand. As a result, fluid is throttled to lower pressures and excess fluid flow is routed directly back to the system reservoir, wasting motor energy and increasing the thermal load on the cooling system. One option for improving the efficiency of older die casting machines currently in use is the retrofit of an adjustable frequency drive, or AFD. An AFD allows the speed of the pump motor to be varied, changing the pump output to suit the cycle demands. This minimizes the amount of wasted energy without affecting other process parameters. This paper will discuss the die casting process and examine the energy savings potential of retrofitting die casting machines with adjustable frequency drives.
Ambs, L.; Kosanovic, D.; Edberg, C.
Tribo-Mechanical Evaluations of Cobalt-Based (Stellite 4) Alloys Manufactured via HIPing and Casting
Abstract � Cobalt-based alloys are known for their excellent wear resistance, particularly under high temperature and corrosive environments. However the cast cobalt-based alloys have relatively high brittleness, and low toughness, due to their coarse carbide structure. This paper aims to comprehend if carbide refinement, caused by changing the processing route from sand casting to powder consolidated Hot Isostatic Pressing (HIPing), can improve the tribo-mechanical properties of cobalt-based alloys. The alloy selected for this investigation had a nominal wt. % composition of Co-30Cr-14W-1C, which is similar to the composition of the commercially available Stellite�4 alloy. The Hot Isostatic Pressed (HIPed) alloy had a much finer microstructure than the cast alloy, which showed a typical hypoeutectic dendritic microstructure. Both alloys had similar hardness. Although the cast alloy showed slightly better abrasive and sliding wear resistance than the HIPed alloy due to their coarser eutectic carbides, the HIPed alloy had a significant advantage on the impact toughness and contact fatigue performance. The results of this comparative investigation indicated that the HIPed alloy had an attractive combination of tribo-mechanical properties, i.e. improved impact and fatigue resistance, whilst preserving the high hardness and good wear resistance associated with the cast alloy, making it suitable for relatively higher stress applications.
H. Yu; R. Ahmed; H. De Villiers Lovelock; S. Davies
International Energy Outlook 1998
8) 8) Dis tri bu tion Cate gory UC-950 In ter na tional En ergy Out look 1998 April 1998 En ergy In for ma tion Ad min istra tion Of fice of In te grated Analy sis and Fore cast ing U.S. De part ment of En ergy Wash ing ton, DC 20585 This re port was pre pared by the En ergy In for ma tion Ad min istra tion, the in de pend ent sta tis ti cal and ana lyti cal agency within the De part ment of En ergy. The in for ma tion con tained herein should be at trib uted to the En ergy In for ma tion Ad min istra tion and should not be con strued as ad vo cat ing or re flect ing any pol icy po si tion of the De part ment of En ergy or of any other or gani za tion. Con tacts The Inter na tional Energy Out look is pre pared by the Energy Infor ma tion Admin istra tion (EIA). Gen eral
NETL: News Release - DOE Transfers Steel Casting Technology to Rock Island
31, 2007 31, 2007 DOE Transfers Steel Casting Technology to Rock Island Arsenal Army Facility to Produce Improved Armor in War on Terrorism WASHINGTON, DC - A steel casting technology developed by the U.S. Department of Energy has been transferred to the U.S. Army's Rock Island Arsenal to manufacture improved armor for vehicles used in the global war on terrorism. MORE INFO Learn more about NETL's cooperative research with the Army The Office of Fossil Energy's National Energy Technology Laboratory (NETL) provided the Rock Island Arsenal with process guidelines, parameters, expertise, and patterns to set up and operate a facility for making steel castings using an NETL-developed process called loose-bonded sand, lost-foam technology. The facilities at the arsenal, in Rock Island, Ill.,
A high resolution finite volume method for efficient parallel simulation of casting processes on unstructured meshes
We discuss selected aspects of a new parallel three-dimensional (3-D) computational tool for the unstructured mesh simulation of Los Alamos National Laboratory (LANL) casting processes. This tool, known as {bold Telluride}, draws upon on robust, high resolution finite volume solutions of metal alloy mass, momentum, and enthalpy conservation equations to model the filling, cooling, and solidification of LANL castings. We briefly describe the current {bold Telluride} physical models and solution methods, then detail our parallelization strategy as implemented with Fortran 90 (F90). This strategy has yielded straightforward and efficient parallelization on distributed and shared memory architectures, aided in large part by new parallel libraries {bold JTpack9O} for Krylov-subspace iterative solution methods and {bold PGSLib} for efficient gather/scatter operations. We illustrate our methodology and current capabilities with source code examples and parallel efficiency results for a LANL casting simulation.
Kothe, D.B.; Turner, J.A.; Mosso, S.J. [Los Alamos National Lab., NM (United States); Ferrell, R.C. [Cambridge Power Computer Assoc. (United States)
Examination of the solidification macrostructure of spheroidal and flake graphite cast irons using DAAS and ESBD
This investigation focuses on the study of the solidification macrostructure of sand cast flake and spheroidal graphite cast irons. The macrostructure is revealed by using a special technique developed earlier by the authors, called Direct Austempering After Solidification. The observations make use of conventional metallography and Electron Back Scattering Diffraction. The latter technique allows a more detailed observation of the morphology of the austenite grains and the microstructure of the matrix. The results of Electron Back Scattering Diffraction validate the observations made using the macrographic technique. It is verified that the solidification of both flake and spheroidal graphite cast irons is dominated by the growth of large austenite dendrites that form a grain pattern similar to that usually found in most metallic alloys.
Rivera, G. [Metallurgy Division INTEMA, National University of Mar del Plata, CONICET, J. B. Justo 4302 (B7608FDQ) Mar del Plata (Argentina); Calvillo, P.R. [Department of Metallurgy and Materials Science, Ghent University (Belgium); Boeri, R. [Metallurgy Division INTEMA, National University of Mar del Plata, CONICET, J. B. Justo 4302 (B7608FDQ) Mar del Plata (Argentina)], E-mail: email@example.com; Houbaert, Y. [Department of Metallurgy and Materials Science, Ghent University (Belgium); Sikora, J. [Metallurgy Division INTEMA, National University of Mar del Plata, CONICET, J. B. Justo 4302 (B7608FDQ) Mar del Plata (Argentina)], E-mail: email@example.com
Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995
The objective of this three-year program is to advance Solarex`s cast polycrystalline silicon manufacturing technology, reduce module production cost, increase module performance and expand Solarex`s commercial production capacities. Two specific objectives of this program are to reduce the manufacturing cost for polycrystalline silicon PV modules to less than $1.20/watt and to increase the manufacturing capacity by a factor of three. To achieve these objectives, Solarex is working in the following technical areas: casting, wire saws, cell process, module assembly, frameless module development, and automated cell handling. Accomplishments reported include: Cast first successful larger ingot producing 73% larger volume of usable Si; Increased the size of the ingot even further and cast an ingot yielding nine 11.4 {times} 11.4 cm bricks, representing a 125% increase in usable Si from a single casting; Operated the wire-saw in a semi-operational mode, producing 459,000 wafers at 94.1% overall yield; Reduced the cost of wire-saw consumables, spare parts, and waste disposal; Developed a cost-effective back surface field process that increases cell efficiency by 5% and began production trials; Developed a plan for increasing the capacity in the module assembly area; Completed qualification testing of modules built using Spire`s automated tabbing and stringing machine; Selected, tested, and qualified a low-cost electrical termination system; Completed long-term UV testing of experimental back sheets; Qualified the structure and adhesive-tape system for mounting frameless modules; and ARRI completed a study of the fracture properties of cast polycrystalline Si wafers and provided the information necessary to calculate the maximum stresses allowable during wafer handling.
Wohlgemuth, J. [Solarex Corp., Frederick, MD (United States)
A numerical study of bench blast row delay timing and its influence on percent-cast
The computer program, DMC (Distinct Motion Code), which was developed for simulating the rock motion associated with blasting, has been used to study the influence of row delay timing on rock motion. The numerical simulations correspond with field observations in that very short delays (< 50ms) and very long delays (> 300ms) produce a lower percent-cast than a medium delay (100 to 200 ms). The DMC predicted relationship between row delay timing and percent-cast is more complex than expected with a dip in the curve where the optimum timing might be expected. More study is required to gain a full understanding of this phenomenon.
Preece, D.S.
Cast CF8C-Plus Stainless Steel for Turbocharger Applications
The purpose of this Cooperative Research and Development Agreement (CRADA) project is to provide the critical test data needed to qualify CF8C-Plus cast stainless steel for commercial production and use for turbocharger housings with upgraded performance and durability relative to standard commercial cast irons or stainless steels. The turbocharger technologies include, but are not limited to, heavy-duty highway diesel engines, and passenger vehicle diesel and gasoline engines. This CRADA provides additional critical high-temperature mechanical properties testing and data analysis needed to quality the new CF8C-Plus steels for turbocharger housing applications.
Maziasz, P.J.; Shyam, A.; Evans, N.D.; Pattabiraman, K. (Honeywell Turbo Technologies
Method For Removing Volatile Components From A Gel-Cast Ceramic Article
A method of removing substantially all of the volatile component in a green, volatile-containing ceramic article is disclosed. The method comprises freezing the ceramic article; and then subjecting the frozen article to a vacuum for a sufficient time to freeze-dry the article. Frequently, the article is heated while being freeze-dried. Use of this method efficiently reduces the propensity for any warpage of the article. The article is often formed from a ceramic slurry in a gel-casting process. A method for fabricating a ceramic core used in investment casting is also described.
Klug, Frederic Joseph (Schenectady, NY); DeCarr, Sylvia Marie (Schenectady, NY)
System and process for the abatement of casting pollution, reclaiming resin bonded sand, and/or recovering a low Btu fuel from castings
Air is caused to flow through the resin bonded mold to aid combustion of the resin binder to form a low Btu gas fuel. Casting heat is recovered for use in a waste heat boiler or other heat abstraction equipment. Foundry air pollutis reduced, the burned portion of the molding sand is recovered for immediate reuse and savings in fuel and other energy is achieved. 5 figs.
Scheffer, K.D.
System and process for the abatement of casting pollution, reclaiming resin bonded sand, and/or recovering a low BTU fuel from castings
Air is caused to flow through the resin bonded mold to aid combustion of the resin binder to form a low BTU gas fuel. Casting heat is recovered for use in a waste heat boiler or other heat abstraction equipment. Foundry air pollution is reduced, the burned portion of the molding sand is recovered for immediate reuse and savings in fuel and other energy is achieved.
Scheffer, Karl D. (121 Governor Dr., Scotia, NY 12302)
Application of self organizing map approach to partial discharge pattern recognition of cast-resin current transformers
Partial discharge (PD) measurement and recognition is a significant tool for potential failure diagnosis of a power transformer. This paper proposes the application of self organizing map (SOM) approach to recognize partial discharge patterns of cast-resin ... Keywords: cast-resin current transformer, partial discharge, pattern recognition, self organizing map
Wen-Yeau Chang; Hong-Tzer Yang
Exergy-based analysis and efficiency evaluation for an aluminum melting furnace in a die-casting plant
The efficiency of a natural gas-fired aluminum melting furnace in a die-casting plant is examined using energy and exergy methods, to improve understanding of the burner system in the furnace and so that potential improvements can be identified. Such ... Keywords: aluminum, die-casting, efficiency, energy, exergy, melting furnace
Marc A. Rosen; Dennis L. Lee
Nondestructive Evaluation: Probabilistic Reliability Model for Thermally Aged Cast Austenitic Stainless Steel Piping
A probabilistic fracture mechanics (PFM) method has been developed to support the evaluation of the effects of thermal aging embrittlement on the reliability of reactor coolant cast austenitic stainless steel (CASS) piping components. The probabilistic method relies on modeling of the contributing elements of a deterministic analysis (for example, geometry, loading conditions, materials, and known degradation ...
Status of the Ultrasonic Examination of Reactor Coolant Loop Cast Stainless Steel Materials
The propagation of ultrasonic energy in cast stainless steel (CSS) materials can be severely inhibited by its grain structure, resulting in unreliable examinations. This report provides an explanation of the difficulties associated with ultrasonic examination of CSS material, reviews several works conducted on ultrasonic examination of CSS materials, and reports the results of ultrasonic examinations conducted on a deep crack in a CSS specimen.
Silica-alumina trihydrate filled epoxy castings resistant to arced SF.sub.6
A cured, insulating, casting composition, having a coefficient of linear thermal expansion of below about 38 .times. 10.sup.-6 in./in./.degree. C and being resistant to arced sulfur hexafluoride gas, in contact with a metal surface in a sulfur hexafluoride gas environment, is made from hydantoin epoxy resin, anhydride curing agent and a filler combination of fused silica and alumina trihydrate.
Chenoweth, Terrence E. (Monroeville, PA); Yeoman, Frederick A. (Murrysville, PA)
The Wettability of LaRC Colorless Polyimide Resins on Casting Surfaces
The effect of inherent viscosity, solids concentration, and solvent choice on the wettability of two colorless polyimides was investigated on various casting surfaces. LaRC-CP1 and LaRC-CP2 are optically transparent, radiation resistant, soluble polyimides ...
Miner Gilda A.; Stoakley Diane M.; Clair Anne K. St.; Gierow Paul A.; Bates Kevin
Cast B2-phase iron-aluminum alloys with improved fluidity
Systems and methods are described for iron aluminum alloys. A composition includes iron, aluminum and manganese. A method includes providing an alloy including iron, aluminum and manganese; and processing the alloy. The systems and methods provide advantages because additions of manganese to iron aluminum alloys dramatically increase the fluidity of the alloys prior to solidification during casting.
Maziasz, Philip J. (122 Clark La., Oak Ridge, TN 37830); Paris, Alan M. (P.O. Box 64, Tarrs, PA 15688); Vought, Joseph D. (124 Cove Point Rd., Rockwood, TN 37854)
E21: Cast Iron Casing Cracking Due to Chunky Graphite Formation
Abstract Scope, In the recent years quality inspection of large turbomachinery casings made of ductile cast ... of chunky graphite formation, methods detection and acceptance criteria. ... A2: Fabrication of Bio-Structures Via Microbubbling ..... Cyclic Sintered Nd-Fe-B Magnets by Transmission Electron Microscopy Analysis.
Graphene/Carbon Nanotube Films Prepared by Solution Casting for Electrochemical Energy Storage
Graphene oxide/carbon nanotube (GO/CNT) films with different CNT contents were prepared by a solution-casting method. The oxygen-containing groups on the GO/CNT films were removed by thermal annealing at 200��C and the corresponding hybrid ...
Juan-Juan Li; Yan-Wen Ma; Xu Jiang; Xiao-Miao Feng; Qu-Li Fan; Wei Huang
Hybrid rendering of dynamic heightfields using ray-casting and mesh rasterization
This paper presents a flexible hybrid method designed to render heightfield data, such as terrains, on GPU. It combines two traditional techniques, namely mesh-based rendering and per-pixel ray-casting. A heuristic is proposed to dynamically choose between ...
Lucas Ammann; Olivier G�nevaux; Jean-Michel Dischler
Certain aspects of the melting, casting and welding of Ni{sub 3}Al alloys
Two alloys under development for castings are IC221M, (nominal composition Ni-8Al-7.7Cr-1.4Mo-1.7Zr wt %), and IC396M (nominal composition Ni-8Al-7.7Cr-3Mo-0.85Zr wt %). These alloys can be melted and cast using the techniques normally used for Ni-based materials. Oxidation of the liquid alloys can be controlled by vacuum processing or inert gas cover during processing. The liquid alloys can react with silica and zircon sands during casting, but this can be controlled through the use of appropriate mold washes like carbon-based materials. Welding studies showed that these alloys are susceptible to solidification cracking in weld fusion zones; the cracks are generally associated with occurrence of Ni-Ni{sub 5}Zr eutectic in interdendritic regions of the weld. Amount of eutectic in the weld microstructures increases with Zr concentration in weld filler metal. Weld filler metal Zr concentrations of 3 wt % and higher prevented solidification cracking of weld deposits on the base casting alloys; This is consistent with accepted phenomonological theory of this process. A weld filler metal with a composition of Ni-8Al-7.7Cr-1.5Mo-3.0Zr wt % was prepared and used to gas tungsten arc weld together 15-mm-thick plates of the IC221M alloy. This weldment was free of cracks. Weldment tensile specimens were machined from the plate and tested at 21, 800, and 900 C. Weldment yield strength at elevated temperatures was higher than room temperature and nearly comparable with that of the base IC221M alloy. Evaluation of the cast Ni{sub 3}Al alloys for furnace furniture, turbocharger rotors, and manufacturing tooling is also briefly discussed.
Santella, M.L.; Sikka, V.K.
Material development in the SI{sub 3}N{sub 4} system using glass encapsulated Hip`ing. Final report, Phase 2: DOE/ORNL Ceramic Technology Project
This report covers a two-year program to develop fully dense Si{sub 3}N{sub 4} matrix SiC whisker composites with enhanced properties over monolithic Si{sub 3}N{sub 4} materials. The primary goal was to develop a composite with a fracture toughness > 10 MPa{radical}m, capable of using high pressure glass encapsulated HIP`ing. Coating methods were developed to apply thin (<150nm) stoichiometric BN layers to SiC whiskers and also to apply a dual coating of SiC over carbon to the whiskers. Fracture toughness of the composites was determined to increase as the quantity of whiskers (or elongated grains) with their axis perpendicular to the crack plane increased. Of the interface compositions evaluated in this effort, carbon was determined to be the most effective for increasing toughness. The highest toughnesses (6.8--7.0 MPa{radical}m) were obtained with uniaxially aligned carbon coated whiskers. There was no evidence of the carbon coating compromising the oxidation resistance of the composites at 1370{degree}C.
Hydraulic fractur ing--also called hy
reported four species of pollinators (Riley, 1892; Davis, 1967; Frack, 1982; Powell, 1984), including three
Goodman, Robert M.
E(Race)ing gender: Stratified identities
In the discussion that follows, I will examine, on the broadest level, Hurston's complex negotiation of identity, as manifested in Their Eyes Were Watching God. Central to this investigation is an understanding of the strategies that women, specifically African American women, have adopted, under the auspices of marriage and the patronage system, to seek an equal place within a hegemonic culture. Most importantly, I want to address the cultural and social price exacted for accepting (as seen in the appropriation of white standards, and rejecting (as seen in Janie's trial for her husband's death) those institutions as the basis of one's identity. The cultural and social price that Janie pays, furthermore, challenges her adaptive capacity to stratify her racial and gender identity. Finally, it exacts a toll on the community as a whole, a fact Hurston repeatedly suggests by illustrating the extent to which the community has absorbed hegemonic standards of value and beauty with little or no inspection of or reflection on the effects to itself or to its individual members.
Nguyen, Le Thuy Thi
te hnology readiness level: 6 a market deliverable has been demonstrated in relevant environments and is in final development . author: alexandra ...
Probing the eV-Mass Range for Solar Axions with CAST
The CERN Axion Solar Telescope (CAST) is searching for solar axions which could be produced in the core of the Sun via the so-called Primakoff effect. Not only would these hypothetical particles solve the strong CP problem, but they are also one of the favored candidates for dark matter. In order to look for axions originating from the Sun, CAST uses a decommissioned LHC prototype magnet. In its 10 m long magnetic field region of 9 Tesla, axions could be reconverted into X-ray photons. Different X-ray detectors are installed on both ends of the magnet, which is mounted on a structure built to follow the Sun during sunrise and sunset for a total of about 3 hours per day. The analysis of the data acquired during the first phase of the experiment with vacuum in the magnetic field region yielded the most restrictive experimental upper limit on the axion-to-photon coupling constant for axion masses up to about 0.02 eV. In order to extend the sensitivity of the experiment to a wider mass range, the CAST experiment continues its search for axions with helium in the magnet bores. In this way it is possible to restore coherence of conversion for larger masses. Changing the pressure of the helium gas enables the experiment to scan different axion masses in the range of up to about 1.2 eV. Especially at high pressures, a precise knowledge of the gas density distribution is crucial to obtain accurate results. In the first part of this second phase of CAST, {sup 4}He was used and the axion mass region was extended up to 0.39 eV, a part of phase space favored by axion models. In CAST's ongoing {sup 3}He phase the studied mass range is now being extended further. In this contribution the final results of CAST's {sup 4}He phase will be presented and the current status of the {sup 3}He run will be given. This includes latest results as well as prospects of future axion experiments.
Vogel, J K; Pivovaroff, M J; Soufli, R; van Bibber, K; CAST, C
Physics-Based Stress Corrosion Cracking Component Reliability Model cast in
Physics-Based Stress Corrosion Cracking Component Reliability Model Physics-Based Stress Corrosion Cracking Component Reliability Model cast in an R7-Compatible Cumulative Damage Framework Physics-Based Stress Corrosion Cracking Component Reliability Model cast in an R7-Compatible Cumulative Damage Framework The Risk-Informed Safety Margin Characterization (RISMC) pathway is a set of activities defined under the U.S. Department of Energy Light Water Reactor Sustainability Program. The overarching objective of RISMC is to support plant life-extension decision-making by providing a state-of-knowledge characterization of safety margins in key systems, structures, and components (SSCs). The methodology emerging from the RISMC pathway is not a conventional probabilistic risk assessment (PRA)-based one; rather, it relies on a reactor systems simulation framework in which
Technical Conference on the Criteria for Designation of NIETCs: Web Cast Final Attendee List
WEB CAST FINAL ATTENDEE LIST WEB CAST FINAL ATTENDEE LIST Ram Adapa EPRI Email: email@example.com Rahul Advani Energy Capital Partners Email: firstname.lastname@example.com Syed Ahmad FERC Email: email@example.com John Ahr Allegheny Power Email: firstname.lastname@example.com Lauren Andersen PJM Email: firstname.lastname@example.com Grace Anderson California Energy Commission Email: email@example.com Christy Appleby PA Office of Consumer Advocate Email: firstname.lastname@example.com Paul Bautista Discovery Insights LLC Email: firstname.lastname@example.com Alan Bax MO Public Service Commission Email: email@example.com David Beam North Carolina Electric Membership Corporation Email: firstname.lastname@example.com Joel Bearden Cargill Power Markets, LLC Email: firstname.lastname@example.com Candace Beery
Patterns of gravity induced aggregate migration during casting of fluid concretes
In this paper, aggregate migration patterns during fluid concrete castings are studied through experiments, dimensionless approach and numerical modeling. The experimental results obtained on two beams show that gravity induced migration is primarily affecting the coarsest aggregates resulting in a decrease of coarse aggregates volume fraction with the horizontal distance from the pouring point and in a puzzling vertical multi-layer structure. The origin of this multi layer structure is discussed and analyzed with the help of numerical simulations of free surface flow. Our results suggest that it finds its origin in the non Newtonian nature of fresh concrete and that increasing casting rate shall decrease the magnitude of gravity induced particle migration.
Spangenberg, J. [Department of Mechanical Engineering, Technical University of Denmark (DTU) (Denmark)] [Department of Mechanical Engineering, Technical University of Denmark (DTU) (Denmark); Roussel, N., E-mail: email@example.com [Universite Paris Est, Laboratoire Central des Ponts et Chaussees (LCPC) (France); Hattel, J.H. [Department of Mechanical Engineering, Technical University of Denmark (DTU) (Denmark)] [Department of Mechanical Engineering, Technical University of Denmark (DTU) (Denmark); Sarmiento, E.V.; Zirgulis, G. [Department of Structural Engineering, Norwegian University of Science and Technology (NTNU) (Norway)] [Department of Structural Engineering, Norwegian University of Science and Technology (NTNU) (Norway); Geiker, M.R. [Department of Structural Engineering, Norwegian University of Science and Technology (NTNU) (Norway) [Department of Structural Engineering, Norwegian University of Science and Technology (NTNU) (Norway); Department of Civil Engineering, Technical University of Denmark (DTU) (Denmark)
Numerical simulation of MHD for electromagnetic edge dam in continuous casting.
A computer model was developed to predict eddy currents and fluid flows in molten steel. The model was verified by comparing predictions with experimental results of liquid-metal containment and fluid flow in electromagnetic (EM) edge dams (EMDs) designed at Inland Steel for twin-roll casting. The model can optimize the EMD design so it is suitable for application, and minimize expensive, time-consuming full-scale testing. Numerical simulation was performed by coupling a three-dimensional (3-D) finite-element EM code (ELEKTRA) and a 3-D finite-difference fluids code (CaPS-EM) to solve heat transfer, fluid flow, and turbulence transport in a casting process that involves EM fields. ELEKTRA is able to predict the eddy-current distribution and the electromagnetic forces in complex geometries. CaPS-EM is capable of modeling fluid flows with free surfaces. Results of the numerical simulation compared measurements obtained from a static test.
Chang, F. C.
Improvements in Sand Mold/Core Technology: Effects on Casting Finish
In this study, the development and impact of density gradients on metal castings were investigated using sand molds/cores from both industry and from in-house production. In spite of the size of the castings market, almost no quantitative information about density variation within the molds/cores themselves is available. In particular, a predictive understanding of how structure and binder content/chemistry/mixing contribute to the final surface finish of these products does not exist. In this program we attempted to bridge this gap by working directly with domestic companies in examining the issues of surface finish and thermal reclamation costs resulting from the use of sand molds/cores. We show that these can be substantially reduced by the development of an in-depth understanding of density variations that correlate to surface finish. Our experimental tools and our experience with them made us uniquely qualified to achieve technical progress.
Prof. John J. Lannutti; Prof. Carroll E. Mobley
Metal casting industry of the future: An integrated approach to delivering energy efficiency products and services
The Industries of the Future process is driven by industry. Through technology roadmaps, industry participants set technology priorities, assess the progress of R and D, and ultimately lead the way in applying research results. This approach to private-public partnerships ensures the most strategic allocation possible of limited resources for the development of new technologies and the enhancement of industrial processes. Based on industry`s request, OIT`s role is to help facilitate the Industries of the Future strategy and to support the development and deployment of technologies that will shape the future of the metal casting industry. Part of this role is to encourage industry to undertake long-term, sector-wide technology planning and to selectively cost-share with OIT in collaborative R and D activities that match OIT`s mission. OIT metal casting research requires a dollar for dollar industry cost share.
Method and apparatus for improved melt flow during continuous strip casting
The continuous casting of metal strip using the melt overflow process is improved by controlling the weir conditions in the nozzle to provide a more uniform flow of molten metal across the width of the nozzle and reducing the tendency for freezing of metal along the interface with refractory surfaces. A weir design having a sloped rear wall and tapered sidewalls and critical gap controls beneath the weir has resulted in the drastic reduction in edge tearing and a significant improvement in strip uniformity. The floor of the container vessel is preferably sloped and the gap between the nozzle and the rotating substrate is critically controlled. The resulting flow patterns observed with the improved casting process have reduced thermal gradients in the bath, contained surface slag and eliminated undesirable solidification near the discharge area by increasing the flow rates at those points.
Follstaedt, Donald W. (Middletown, OH); King, Edward L. (Trenton, OH); Schneider, Ken C. (Dayton, OH)
Separate effects identification via casting process modeling for experimental measurement of U�Pu�Zr alloys
Computational simulations of gravity casting processes for metallic U�Pu�Zr nuclear fuel rods have been performed using a design-of-experiments technique to determine the fluid flow, liquid heat transfer, and solid heat transfer parameters which most strongly influence the process solidification speed and fuel rod porosity. The results are used to make recommendations for the best investment of experimental time and effort to measure process parameters.
J. Crapps; D. S. DeCroix; J. D. Galloway; D. A. Korzekwa; R. Aikin; R. Fielding; R. Kennedy; C. Unal
Mechanical properties of thermally aged cast stainless steels from Shippingport reactor components
Thermal embrittlement of static-cast CF-8 stainless steel components from the decommissioned Shippingport reactor has been characterized. Cast stainless steel materials were obtained from four cold-leg check valves, three hot-leg main shutoff valves, and two pump volutes. The actual time-at-temperature for the materials was {approximately}13 y at {approximately}281 C (538 F) for the hot-leg components and {approximately}264 C (507 F) for the cold-leg components. Baseline mechanical properties for as-cast material were determined from tests on either recovery-annealed material, i.e., annealed for 1 h at 550 C and then water quenched, or material from the cooler region of the component. The Shippingport materials show modest decreases in fracture toughness and Charpy-impact properties and a small increase in tensile strength because of relatively low service temperatures and ferrite content of the steel. The procedure and correlations developed at Argonne National Laboratory for estimating mechanical properties of cast stainless steels predict accurate or slightly lower values for Charpy-impact energy, tensile flow stress, fracture toughness J-R curve, and J{sub IC} of the materials. The kinetics of thermal embrittlement and degree of embrittlement at saturation, i.e., the minimum impact energy achieved after long-term aging, were established from materials that were aged further in the laboratory. The results were consistent with the estimates. The correlations successfully predicted the mechanical properties of the Ringhals 2 reactor hot and crossover-leg elbows (CF-8M steel) after service of {approximately} 15 y and the KRB reactor pump cover plate (CF-8) after {approximately} 8 y of service.
Chopra, O.K.; Shack, W.J. [Argonne National Lab., IL (United States)
Energy Saving Melting and Revert Reduction Technology: Aging of Graphitic Cast Irons and Machinability
The objective of this task was to determine whether ductile iron and compacted graphite iron exhibit age strengthening to a statistically significant extent. Further, this effort identified the mechanism by which gray iron age strengthens and the mechanism by which age-strengthening improves the machinability of gray cast iron. These results were then used to determine whether age strengthening improves the machinability of ductile iron and compacted graphite iron alloys in order to develop a predictive model of alloy factor effects on age strengthening. The results of this work will lead to reduced section sizes, and corresponding weight and energy savings. Improved machinability will reduce scrap and enhance casting marketability. Technical Conclusions: �?�?�?¢�?�?�?�?�?�?�?¢ Age strengthening was demonstrated to occur in gray iron ductile iron and compacted graphite iron. �?�?�?¢�?�?�?�?�?�?�?¢ Machinability was demonstrated to be improved by age strengthening when free ferrite was present in the microstructure, but not in a fully pearlitic microstructure. �?�?�?¢�?�?�?�?�?�?�?¢ Age strengthening only occurs when there is residual nitrogen in solid solution in the Ferrite, whether the ferrite is free ferrite or the ferrite lamellae within pearlite. �?�?�?¢�?�?�?�?�?�?�?¢ Age strengthening can be accelerated by Mn at about 0.5% in excess of the Mn/S balance Estimated energy savings over ten years is 13.05 trillion BTU, based primarily on yield improvement and size reduction of castings for equivalent service. Also it is estimated that the heavy truck end use of lighter castings for equivalent service requirement will result in a diesel fuel energy savings of 131 trillion BTU over ten years.
Von L. Richards
Cast polycrystalline silicon photovoltaic cell and module manufacturing technology improvements. Annual subcontract report, 1 December 1993--30 November 1994
This report describes work performed under a 3-y contract to advance Solarex`s cast polycrystalline silicon manufacturing technology, reduce module production cost, increase module performance, and expand Solarex`s commercial production capacities. Specific objectives are to reduce manufacturing cost for polycrstalline silicon PV modules to less than $1.20/W and to increase manufacturing capacity by a factor of 3. Solarex is working on casting, wire saws, cell process, module assembly, frameless module development, and automated cell handling.
Evaluation of residual stress gradients in ductile cast iron using critical refracted longitudinal (Lcr) wave technique
Critically refracted longitudinal (LCR) waves have been investigated as a possible technique for the evaluation of the residual stress gradients present in ductile iron castings. Residual stresses are likely to develop in ductile cast iron during the cooling phase of a casting process. A LCR probe fabricated for previous research was used to make the velocity measurements. The samples investigated were of different modularity and two were annealed while one was not. The samples were milled at increments of approximately two millimeters and the LCR velocities were taken-at each increment. This provided data for the mapping of velocity versus depth which represents the residual stress gradient. To confirm the presence of the residual stress gradient, strain gages were attached to similar samples and the samples were saw cut with the intent to relieve residual stresses. The strain gages indicated that residual stresses were relieved by the sawcutting. The strain gage data was found to support the LCR velocity map to an extent. Both sets of data indicate compressive stresses on the surface. The data also allowed for an evaluation of the annealing procedure used. The results showed that even after full annealing remnant stresses are still present in the bars tested.
Pfluger, Ron Atlan
Energy Saving Melting and Revert Reduction Technology: Melting Efficiency in Die Casting Operations
This project addressed multiple aspects of the aluminum melting and handling in die casting operations, with the objective of increasing the energy efficiency while improving the quality of the molten metal. The efficiency of melting has always played an important role in the profitability of aluminum die casting operations. Consequently, die casters need to make careful choices in selecting and operating melting equipment and procedures. The capital cost of new melting equipment with higher efficiency can sometimes be recovered relatively fast when it replaces old melting equipment with lower efficiency. Upgrades designed to improve energy efficiency of existing equipment may be well justified. Energy efficiency is however not the only factor in optimizing melting operations. Melt losses and metal quality are also very important. Selection of melting equipment has to take into consideration the specific conditions at the die casting shop such as availability of floor space, average quantity of metal used as well as the ability to supply more metal during peaks in demand. In all these cases, it is essential to make informed decisions based on the best available data.
David Schwam
Structure and composition of nanometer-sized nitrides in a creep resistant cast austenitic alloy
The microstructure of a new and improved high-temperature creep-resistant cast austenitic alloy, CF8C-Plus, was characterized after creep-rupture testing at 1023 K (750 C) and 100 MPa. Microstructures were investigated by detailed scanning electron microscopy, transmission electron microscopy, and energy-dispersive X-ray spectroscopy (EDS). Principal component analysis of EDS spectrum images was used to examine the complex precipitate morphology. Thermodynamic modeling was performed to predict equilibrium phases in this alloy as well as the compositions of these phases at relevant temperatures. The improved high-temperature creep strength of CF8C-Plus over its predecessor CF8C is suggested to be due to the modified microstructure and phase stability in the alloy, including the absence of {delta}-ferrite in the as-cast condition and the development of a stable, slow-growing precipitation hardening nitride phase - the tetragonal Z-phase - which has not been observed before in cast austenitic stainless steels.
Evans, Neal D [ORNL; Maziasz, Philip J [ORNL; Shingledecker, John P. [Electric Power Research Institute (EPRI); Pollard, Michael J [Caterpillar Technical Center
Permanent Mold Casting of JIS-AC4C Aluminum Alloy Using a Low-Temperature Mold
Permanent mold casting using mold temperatures below 200 deg. C was conducted to obtain a high-strength, thin-walled casting. Al-7.36 mass% Si -0.18 Cu- 0.27Mg-0.34Fe alloy JIS-AC4C was cast using a bottom pouring cast plan. The product had a rectangular tube shape (70 mm W x 68 mm D x 180 mm H) with wall thicknesses of 1, 3 and 5 mm. The effect of heat insulation at the melt path was compared when using a sand runner insert and when using a steel runner insert as well as a powder mold release agent. Fine microstructures were observed in the casting. The smaller the thickness, the higher the hardness with smaller secondary dendrite arm spacing (SDAS). However, the hardness and the SDAS were unaffected by the mold temperature. It was proposed that the avoidance of the formation of primary {alpha} dendrite at the melt path generates a higher strength casting with adequate mold filling.
Yamagata, Hiroshi; Nikawa, Makoto
Utilities in the U.S. operate over 75,000 km (47,000 miles) of old cast-iron pipes for gas distribution. The bell-and-spigot joints that connect pipe sections together tend to leak as these pipes age. Current repair practices are costly and highly disruptive. The objective of this program is to design, test and commercialize a robotic system capable of sealing multiple cast-iron bell and spigot joints from a single pipe entry point. The proposed system will perform repairs while the pipe remains in service by traveling through the pipe, cleaning each joint surface, and installing a stainless-steel sleeve lined with an epoxy-impregnated felt across the joint. This approach will save considerable time and labor, avoid traffic disruption, and eliminate any requirement to interrupt service to customers (which would result in enormous expense to utilities). Technical challenges include: (1) repair sleeves must compensate for diametric variation and eccentricity of cast-iron pipes; (2) the assembly must travel long distances through pipes containing debris; (3) the pipe wall must be effectively cleaned in the immediate area of the joint to assure good bonding of the sleeve; and (4) an innovative bolt-on entry fitting is required to conduct repair operations on live mains. The development effort is divided into eleven tasks. Task 1--Program Management and Task 2--were completed in prior quarters while Task 3--Design and Fabricate Ratcheting Stainless-Steel Repair Sleeves has progressed to installing prototype sleeves in cast iron test pipe segments. Efforts in this quarter continued to focus on Tasks 4--8, with significant progress made in each. Task 4 (Design, Fabricate and Test Patch Setting Robotic Train) progressed to the design of the control electronics and pneumatic system to inflate the bladder robotic patch setting module. Task 5 (Design & Fabricate Pipe-Wall Cleaning Robot Train with Pan/Zoom/Tilt Camera) continued with additional in-pipe testing required to optimize the design of the robot elements and surface control electronics and software. Task 6 (Design & Build Surface Control and Monitoring System) has been completed with the control and computer display functions being operated through LabView. Task 7 (Design & Fabricate Large Diameter Live Access System) progressed to completing the detailed design of the entry fitting for 12-inch diameter cast iron pipe. The fitting is now being placed into manufacture. Task 8--System Integration and Laboratory Validation continued developing the robot module inter-connects and development of a master LabView-based system display and control software.
Kiran M. Kothari; Gerard T. Pittard
pn-CCDs in a Low-Background Environment: Detector Background of the CAST X-ray Telescope
The CAST experiment at CERN (European Organization of Nuclear Research) searches for axions from the sun. The axion is a pseudoscalar particle that was motivated by theory thirty years ago, with the intention to solve the strong CP problem. Together with the neutralino, the axion is one of the most promising dark matter candidates. The CAST experiment has been taking data during the last two years, setting an upper limit on the coupling of axions to photons more restrictive than from any other solar axion search in the mass range below 0.1 eV. In 2005 CAST will enter a new experimental phase extending the sensitivity of the experiment to higher axion masses. The CAST experiment strongly profits from technology developed for high energy physics and for X-ray astronomy: A superconducting prototype LHC magnet is used to convert potential axions to detectable X-rays in the 1-10 keV range via the inverse Primakoff effect. The most sensitive detector system of CAST is a spin-off from space technology, a Wolter I type X-ray optics in combination with a prototype pn-CCD developed for ESA's XMM-Newton mission. As in other rare event searches, background suppression and a thorough shielding concept is essential to improve the sensitivity of the experiment to the best possible. In this context CAST offers the opportunity to study the background of pn-CCDs and its long term behavior in a terrestrial environment with possible implications for future space applications. We will present a systematic study of the detector background of the pn-CCD of CAST based on the data acquired since 2002 including preliminary results of our background simulations.
M. Kuster; S. Cebrian; A. Rodriquez; R. Kotthaus; H. Braeuninger; J. Franz; P. Friedrich; R. Hartmann; D. Kang; G. Lutz; L. Strueder
Results and perspectives of the solar axion search with the CAST experiment
The status of the solar axion search with the CERN Axion Solar Telescope (CAST) will be presented. Recent results obtained by the use of $^3$He as a buffer gas has allowed us to extend our sensitivity to higher axion masses than our previous measurements with $^4$He. With about 1 h of data taking at each of 252 different pressure settings we have scanned the axion mass range 0.39 eV$ \\le m_{a} \\le $ 0.64 eV. From the absence of an excess of x rays when the magnet was pointing to the Sun we set a typical upper limit on the axion-photon coupling of g$_{a\\gamma} \\le 2.3\\times 10^{-10}$ GeV$^{-1}$ at 95% C.L., the exact value depending on the pressure setting. CAST published results represent the best experimental limit on the photon couplings to axions and other similar exotic particles dubbed WISPs (Weakly Interacting Slim Particles) in the considered mass range and for the first time the limit enters the region favored by QCD axion models. Preliminary sensitivities for axion masses up to 1.16 eV will also be shown reaching mean upper limits on the axion-photon coupling of g$_{a\\gamma} \\le 3.5\\times 10^{-10}$ GeV$^{-1}$ at 95% C.L. Expected sensibilities for the extension of the CAST program up to 2014 will be presented. Moreover long term options for a new helioscope experiment will be evoked.
E. Ferrer-Ribas; M. Arik; S. Aune; K. Barth; A. Belov; S. Borghi; H. Br�uninger; G. Cantatore; J. M. Carmona; S. A. Cetin; J. I. Collar; T. Dafni; M. Davenport; C. Eleftheriadis; N. Elias; C. Ezer; G. Fanourakis; P. Friedrich; J. Gal�n; J. A. Garc�a; A. Gardikiotis; J. G. Garza; E. N. Gazis; T. Geralis; I. Giomataris; S. Gninenko; H. G�mez; E. Gruber; T. Guth�rl; R. Hartmann; F. Haug; M. D. Hasinoff; D. H. H. Hoffmann; F. J. Iguaz; I. G. Irastorza; J. Jacoby; K. Jakov\\vci?; M. Karuza; K. K�nigsmann; R. Kotthaus; M. Kr?mar; M. Kuster; B. Laki?; J. M. Laurent; A. Liolios; A. Ljubi?i?; V. Lozza; G. Lutz; G. Luz�n; J. Morales; T. Niinikoski; A. Nordt; T. Papaevangelou; M. J. Pivovaroff; G. Raffelt; T. Rashba; H. Riege; A. Rodr�guez; M. Rosu; J. Ruz; I. Savvidis; P. S. Silva; S. K. Solanki; L. Stewart; A. Tom�s; M. Tsagri; K. van Bibber; T. Vafeiadis; J. Villar; J. K. Vogel; S. C. Yildiz; K. Zioutas
Secondary Waste Form Screening Test Results�Cast Stone and Alkali Alumino-Silicate Geopolymer
PNNL is conducting screening tests on the candidate waste forms to provide a basis for comparison and to resolve the formulation and data needs identified in the literature review. This report documents the screening test results on the Cast Stone cementitious waste form and the Geopolymer waste form. Test results suggest that both the Cast Stone and Geopolymer appear to be viable waste forms for the solidification of the secondary liquid wastes to be treated in the ETF. The diffusivity for technetium from the Cast Stone monoliths was in the range of 1.2 � 10-11 to 2.3 � 10-13 cm2/s during the 63 days of testing. The diffusivity for technetium from the Geopolymer was in the range of 1.7 � 10-10 to 3.8 � 10-12 cm2/s through the 63 days of the test. These values compare with a target of 1 � 10-9 cm2/s or less. The Geopolymer continues to show some fabrication issues with the diffusivities ranging from 1.7 � 10-10 to 3.8 � 10-12 cm2/s for the better-performing batch to from 1.2 � 10-9 to 1.8 � 10-11 cm2/s for the poorer-performing batch. In the future more comprehensive and longer term performance testing will be conducted, to further evaluate whether or not these waste forms will meet the regulation and performance criteria needed to cost-effectively dispose of secondary wastes.
Pierce, Eric M.; Cantrell, Kirk J.; Westsik, Joseph H.; Parker, Kent E.; Um, Wooyong; Valenta, Michelle M.; Serne, R. Jeffrey
Grain refinement and texture development of cast bi90sb10 alloy via severe plastic deformation
The purpose of this work was to study learn about grain refinement mechanisms and texture development in cast n-type Bi90Sb10 alloy caused by severe plastic deformation. The practical objective is to produce a fine grained and textured microstructure in Bi90Sb10 alloy with enhanced thermoelectric performance and mechanical strength. In the study, twelve millimeter diameter cast bars of Bi90Sb10 alloy were encapsulated in square cross section aluminum 6061 alloy containers. The composite bars were equal channel angular (ECAE) extruded through a 90 degree angle die at high homologous temperature. Various extrusion conditions were studied including punch speed (0.1, 0.3 and 0.6 in/min), extrusion temperature (220, 235 and 250oC), number of extrusion passes (1, 2 and 4), route (A, BC and C), and exit channel area reduction ratio (half and quarter area of inlet channel). The affect of an intermediate long term heat treatment (for 100 hours at 250oC under 10-3 torr vacuum) was explored. Processed materials were characterized by optical microscopy, x-ray diffraction, energy dispersive spectroscopy, wavelength dispersive spectroscopy and scanning electron microscopy. Texture was analyzed using the {006} reflection plane to identify the orientation of the basal poles in processed materials. The cast grains were irregularly shaped, had a grain size of hundreds-of-microns to millimeters, and showed inhomogeneous chemical composition. Severe plastic deformation refines the cast grains through dynamic recrystallization and causes the development of a bimodal microstructure consisting of fine grains (5-30 micron) and coarse grains (50-300 micron). ECAE processing of homogenizied Bi-Sb alloy causes grain refinement and produces a more uniform microstructure. Texture results show that ECAE route C processing gives a similar or slightly stronger texture than ECAE route A processing. In both cases, the basal-plane poles become aligned with the shear direction. Reduction area exit channel extrusion is more effective for both grain refinement and texture enhancement than simple ECAE processing.
Im, Jae-taek
The rate of oxidation is important to the long-term performance of reducing salt waste forms because the solubility of some contaminants, e.g., technetium, is a function of oxidation state. TcO{sub 4}{sup ?} in the salt solution is reduced to Tc(IV) and has been shown to react with ingredients in the waste form to precipitate low solubility sulfide and/or oxide phases. Upon exposure to oxygen, the compounds containing Tc(IV) oxidize to the pertechnetate ion, Tc(VII)O{sub 4}{sup ?}, which is very soluble. Consequently the rate of technetium oxidation front advancement into a monolith and the technetium leaching profile as a function of depth from an exposed surface are important to waste form performance and ground water concentration predictions. An approach for measuring contaminant oxidation rate (effective contaminant specific oxidation rate) based on leaching of select contaminants of concern is described in this report. In addition, the relationship between reduction capacity and contaminant oxidation is addressed. Chromate (Cr(VI) was used as a non-radioactive surrogate for pertechnetate, Tc(VII), in Cast Stone samples prepared with 5 M Simulant. Cast Stone spiked with pertechnetate was also prepared and tested. Depth discrete subsamples spiked with Cr were cut from Cast Stone exposed to Savannah River Site (SRS) outdoor ambient temperature fluctuations and moist air. Depth discrete subsamples spiked with Tc-99 were cut from Cast Stone exposed to laboratory ambient temperature fluctuations and moist air. Similar conditions are expected to be encountered in the Cast Stone curing container. The leachability of Cr and Tc-99 and the reduction capacities, measured by the Angus-Glasser method, were determined for each subsample as a function of depth from the exposed surface. The results obtained to date were focused on continued method development and are preliminary and apply to the sample composition and curing / exposure conditions described in this report. � The Cr oxidation front (depth to which soluble Cr was detected) for the Cast Stone sample exposed for 68 days to ambient outdoor temperatures and humid air (total age of sample was 131 days) was determined to be about 35 mm below the top sample surface exposed. The Tc oxidation front, depth at which Tc was insoluble, was not determined. Interpretation of the results indicates that the oxidation front is at least 38 mm below the exposed surface. The sample used for this measurement was exposed to ambient laboratory conditions and humid air for 50 days. The total age of the sample was 98 days. � Technetium appears to be more easily oxidized than Cr in the Cast Stone matrix. The oxidized forms of Tc and Cr are soluble and therefore leachable. Longer exposure times are required for both the Cr and Tc spiked samples to better interpret the rate of oxidation. Tc spiked subsamples need to be taken further from the exposed surface to better define and interpret the leachable Tc profile. � Finally Tc(VII) reduction to Tc(IV) appears to occur relatively fast. Results demonstrated that about 95 percent of the Tc(VII) was reduced to Tc(IV) during the setting and very early stage setting for a Cast Stone sample cured 10 days. Additional testing at longer curing times is required to determine whether additional time is required to reduce 100 % of the Tc(VII) in Cast Stone or whether the Tc loading exceeded the ability of the waste form to reduce 100 % of the Tc(VII). Additional testing is required for samples cured for longer times. Depth discrete subsampling in a nitrogen glove box is also required to determine whether the 5 percent Tc extracted from the subsamples was the result of the sampling process which took place in air. Reduction capacity measurements (per the Angus-Glasser method) performed on depth discrete samples could not be correlated with the amount of chromium or technetium leached from the depth discrete subsamples or with the oxidation front inferred from soluble chromium and technetium (i.e., effective Cr and Tc oxidation fronts). Residual reduct
Langton, C.
Utilities in the U.S. operate over 75,000 km (47,000 miles) of old cast-iron pipes for gas distribution. The bell-and-spigot joints that connect pipe sections together tend to leak as these pipes age. Current repair practices are costly and highly disruptive. The objective of this program is to design, test and commercialize a robotic system capable of sealing multiple castiron bell and spigot joints from a single pipe entry point. The proposed system will perform repairs while the pipe remains in service by traveling through the pipe, cleaning each joint surface, and installing a stainless-steel sleeve lined with an epoxy-impregnated felt across the joint. This approach will save considerable time and labor, avoid traffic disruption, and eliminate any requirement to interrupt service to customers (which would result in enormous expense to utilities). Technical challenges include: (1) repair sleeves must compensate for diametric variation and eccentricity of cast-iron pipes; (2) the assembly must travel long distances through pipes containing debris; (3) the pipe wall must be effectively cleaned in the immediate area of the joint to assure good bonding of the sleeve; and (4) an innovative bolt-on entry fitting is required to conduct repair operations on live mains. The development effort is divided into eleven tasks. Task 1 (Program Management) and Task 2 (Establishment of Detailed Design Specifications) were completed in prior quarters while Task 3 (Design and Fabricate Ratcheting Stainless-Steel Repair Sleeves) has progressed to installing prototype sleeves in cast iron test pipe segments. Efforts in this quarter continued to focus on Tasks 4-8, with significant progress made in each. Task 4 (Design, Fabricate and Test Patch Setting Robotic Train) progressed to the design of the control electronics and pneumatic system to inflate the bladder robotic patch setting module. Task 5 (Design & Fabricate Pipe-Wall Cleaning Robot Train with Pan/Zoom/Tilt Camera) continued with additional in-pipe testing required to optimize the design of the robot elements and surface control electronics and software. Task 6 (Design & Build Surface Control and Monitoring System) has been completed with the control and computer display functions being operated through LabView. Task 7 (Design & Fabricate Large Diameter Live Access System) progressed to completing the detailed design of the entry fitting for 12-inch diameter cast iron pipe. The fitting is now being manufactured. The 12-inch ball valve for allowing no-blow access was also procured. Task 8 (System Integration and Laboratory Validation) continued with the development of the robot module inter-connects and of a master LabView-based system display and control software.
Kiran M Kothari; Gerard T. Pittard
Utilities in the U.S. operate over 75,000 km (47,000 miles) of old cast-iron pipes for gas distribution. The bell-and-spigot joints that connect pipe sections together tend to leak as these pipes age. Current repair practices are costly and highly disruptive. The objective of this program is to design, test and commercialize a robotic system capable of sealing multiple cast iron bell and spigot joints from a single pipe entry point. The proposed system will perform repairs while the pipe remains in service by traveling through the pipe, cleaning each joint surface, and installing a stainless-steel sleeve lined with an epoxy-impregnated felt across the joint. This approach will save considerable time and labor, avoid traffic disruption, and eliminate any requirement to interrupt service to customers (which would result in enormous expense to utilities). Technical challenges include: (1) repair sleeves must compensate for diametric variation and eccentricity of cast-iron pipes; (2) the assembly must travel long distances through pipes containing debris; (3) the pipe wall must be effectively cleaned in the immediate area of the joint to assure good bonding of the sleeve; and (4) an innovative bolt-on entry fitting is required to conduct repair operations on live mains. The development effort is divided into eleven tasks. Task 1--Program Management and Task 2--were completed in prior quarters while Task 3--Design and Fabricate Ratcheting Stainless-Steel Repair Sleeves has progressed to installing prototype sleeves in cast iron test pipe segments. Efforts in this quarter continued to focus on Tasks 4--8, with significant progress made in each. Task 4 (Design, Fabricate and Test Patch Setting Robotic Train) progressed to the design of the control electronics and pneumatic system to inflate the bladder robotic patch setting module. Task 5 (Design & Fabricate Pipe-Wall Cleaning Robot Train with Pan/Zoom/Tilt Camera) continued with additional in-pipe testing required to optimize the design of the robot elements and surface control electronics and software. Task 6 (Design & Build Surface Control and Monitoring System) has been completed with the control and computer display functions being operated through LabView. Task 7 (Design & Fabricate Large Diameter Live Access System) progressed to the design, fabrication and testing of a entry fitting in a 4-inch prototype and is now being used to complete drawings for use in 12-inch diameter pipe. Task 8--System Integration and Laboratory Validation continued developing the robot module inter-connects and development of a master LabView-based system display and control software.
Kiran M. Kothari, Gerard T. Pittard
Development of NZP ceramic based {open_quotes}cast-in-place{close_quotes} diesel engine port liners
BSX (Ba{sub 1+x}Zr{sub 4}P{sub 6-2x}Si{sub 2x}O{sub 24}) and CSX (Ca{sub l-x}Sr{sub x}Zr{sub 4}P{sub 6}O{sub 24}) type NZP ceramics were fabricated and characterized for: (i) thermal properties viz., thermal conductivity, thermal expansion, thermal stability and thermal shock resistance; (ii) mechanical properties viz., flexure strength and elastic modulus; and (iii) microstructures. Results of these tests and analysis indicated that the BS-25 (x=0.25 in BSX) and CS-50 (x=0.50 in CSX) ceramics had the most desirable properties for casting metal with ceramic in place. Finite element analysis (FEA) of metal casting (with ceramic in place) was conducted to analyze thermomechanical stresses generated and determine material property requirements. Actual metal casting trials were also conducted to verify the results of finite element analysis. In initial trials, the ceramic cracked because of the large thermal expansion mismatch (hoop) stresses (predicted by FEA also). A process for introduction of a compliant layer between the metal and ceramic to alleviate such destructive stresses was developed. The compliant layer was successful in preventing cracking of either the ceramic or the metal. In addition to these achievements, pressure slip casting and gel-casting processes for fabrication of NZP components; and acoustic emission and ultrasonics-based NDE techniques for detection of microcracks and internal flaws, respectively, were successfully developed.
Nagaswaran, R.; Limaye, S.Y.
Energy Saving Melting and Revert Reduction Technology (Energy SMARRT): Manufacturing Advanced Engineered Components Using Lost Foam Casting Technology
This project was a subtask of Energy Saving Melting and Revert Reduction Technology (�?¢�?�?�?�?Energy SMARRT�?¢�?�?�?) Program. Through this project, technologies, such as computer modeling, pattern quality control, casting quality control and marketing tools, were developed to advance the Lost Foam Casting process application and provide greater energy savings. These technologies have improved (1) production efficiency, (2) mechanical properties, and (3) marketability of lost foam castings. All three reduce energy consumption in the metals casting industry. This report summarizes the work done on all tasks in the period of January 1, 2004 through June 30, 2011. Current (2011) annual energy saving estimates based on commercial introduction in 2011 and a market penetration of 97% by 2020 is 5.02 trillion BTU�?¢�?�?�?�?s/year and 6.46 trillion BTU�?¢�?�?�?�?s/year with 100% market penetration by 2023. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology. The average annual estimate of CO2 reduction per year through 2020 is 0.03 Million Metric Tons of Carbon Equivalent (MM TCE).
Harry Littleton; John Griffin
...Alloy C355.0 Air-compressor fittings, crankcases, gear housings Alloy A356.0 Automobile transmission cases, oil pans, and rear-axle
Method of improving fatigue life of cast nickel based superalloys and composition
The invention consists of a method of producing a fine equiaxed grain structure (ASTM 2-4) in cast nickel-base superalloys which increases low cycle fatigue lives without detrimental effects on stress rupture properties to temperatures as high as 1800.degree. F. These superalloys are variations of the basic nickel-chromium matrix, hardened by gamma prime [Ni.sub.3 (Al, Ti)] but with optional additions of cobalt, tungsten, molybdenum, vanadium, columbium, tantalum, boron, zirconium, carbon and hafnium. The invention grain refines these alloys to ASTM 2 to 4 increasing low cycle fatigue life by a factor of 2 to 5 (i.e. life of 700 hours would be increased to 1400 to 3500 hours for a given stress) as a result of the addition of 0.01% to 0.2% of a member of the group consisting of boron, zirconium and mixtures thereof to aid heterogeneous nucleation. The alloy is vacuum melted and heated to 250.degree.-400.degree. F. above the melting temperature, cooled to partial solidification, thus resulting in said heterogeneous nucleation and fine grains, then reheated and cast at about 50.degree.-100.degree. F. of superheat. Additions of 0.1% boron and 0.1% zirconium (optional) are the preferred nucleating agents.
Denzine, Allen F. (Chardon, OH); Kolakowski, Thomas A. (Cleveland, OH); Wallace, John F. (Shaker Heights, OH)
Utilities in the U.S. operate over 75,000 km (47,000 miles) of old cast-iron pipes for gas distribution. Bell-and-spigot joints that connect pipe sections together tend to leak as these pipes age. Current repair practices are costly and highly disruptive. The objective of this program is to design, test and commercialize a robotic system capable of sealing multiple castiron bell and spigot joints from a single pipe entry point. The proposed system will perform repairs with the pipe in service by traveling through the pipe, cleaning each joint surface, and installing a stainless-steel sleeve lined with an epoxy-impregnated felt across the joint. This approach will save considerable time and labor, minimize excavation, avoid traffic disruption, and eliminate any requirement to interrupt service to customers (which would result in enormous expense to utilities). Technical challenges include: (1) repair sleeves must compensate for diametric variation and eccentricity of old cast-iron pipes; (2) the assembly must travel long distances through pipes containing debris; (3) the pipe wall must be effectively cleaned in the immediate area of the joint to assure good bonding of the sleeve; and (4) an innovative bolt-on entry fitting is required to conduct safe repair operations on live mains.
A casting and imaging technique for determining void geometry and relative permeability behavior of a single fracture specimen
A casting technique has been developed for making translucent replicas of the void space of natural rock fractures. Attenuation of light shined through the cast combined with digital image analysis provides a pointwise definition of fracture apertures. The technique has been applied to a fracture specimen from Dixie Valley, Nevada, and the measured void space geometry has been used to develop theoretical predictions of two-phase relative permeability. A strong anisotropy in relative permeabilities has been found, which is caused by highly anisotropic spatial correlations among fracture apertures. 16 refs., 6 figs.
Cox, B.L.; Pruess, K.; Persoff, P.
Report of Separate Effects Testing for Modeling of Metallic Fuel Casting Process
In order to give guidance regarding the best investment of time and effort in experimental determination of parameters defining the casting process, a Flow-3D model of the casting process was used to investigate the most influential parameters regarding void fraction of the solidified rods and solidification speed for fluid flow parameters, liquid heat transfer parameters, and solid heat transfer parameters. Table 1 summarizes the most significant variables for each of the situations studied. A primary, secondary, and tertiary effect is provided for fluid flow parameters (impacts void fraction) and liquid heat transfer parameters (impacts solidification). In Table 1, the wetting angle represents the angle between the liquid and mold surface as pictured in Figure 1. The viscosity is the dynamic viscosity of the liquid and the surface tension is the property of the surface of a liquid that allows it to resist an external force. When only considering solid heat transfer properties, the variations from case to case were very small. Details on this conclusion are provided in the section considering solid heat transfer properties. The primary recommendation of the study is to measure the fluid flow parameters, specifically the wetting angle, surface tension, and dynamic viscosity, in order of importance, as well as the heat transfer parameters latent heat and specific heat of the liquid alloy. The wetting angle and surface tension can be measured simultaneously using the sessile drop method. It is unclear whether there is a temperature dependency in these properties. Thus measurements for all three parameters are requested at 1340, 1420, and 1500 degrees Celsius, which correspond to the minimum, middle, and maximum temperatures of the liquid alloy during the process. In addition, the heat transfer coefficient between the mold and liquid metal, the latent heat of transformation, and the specific heat of the liquid metal all have strong influences on solidification. These parameters should be measured to achieve better simulation fidelity. Information on all the mentioned parameters is virtually nonexistent. Presently, all the parameters within the casting model are estimates based on pure U, or another alloy such as U-Ni.
Crapps, Justin M. [Los Alamos National Laboratory; Galloway, Jack D. [Los Alamos National Laboratory; Decroix, David S. [Los Alamos National Laboratory; Korzekwa, David A. [Los Alamos National Laboratory; Aikin, Robert M. Jr. [Los Alamos National Laboratory; Unal, Cetin [Los Alamos National Laboratory; Fielding, R. [Idaho National Laboratory; Kennedy, R [Idaho National Laboratory
Prediction and Optimization of a Ceramic Casting Process Using A Hierarchical Hybrid System of Neural Networks and Fuzzy Logic
optimization for use in the ceramics industry. A prediction module estimates two quality metrics of slipPrediction and Optimization of a Ceramic Casting Process Using A Hierarchical Hybrid System)1 Department of Industrial and Systems Engineering Dunstan Hall Auburn University Auburn University
Smith, Alice E.
Brittle Failure Design Criteria for Ductile Cast Iron Spent-Fuel
r r Recommendations for Ductile and Brittle Failure Design Criteria for Ductile Cast Iron Spent-Fuel Shipping Containers This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsi- bility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Refer- ence herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recom-
HEU Holdup Measurements in 321-M B and Spare U-Al Casting Furnaces
The Analytical Development Section of Savannah River Technology Center (SRTC) was requested by the Facilities Decontamination Division (FDD) to determine the holdup of enriched uranium in the 321-M facility as part of an overall deactivation project of the facility. The 321-M facility was used to fabricate enriched uranium fuel assemblies, lithium-aluminum target tubes, neptunium assemblies, and miscellaneous components for the production reactors. This report covers holdup measurements in two uranium aluminum alloy (U-Al) casting furnaces. Our results indicate an upper limit of 235U content for the B and Spare furnaces of 51 and 67 g respectively. This report discusses the methodology, non-destructive assay (NDA) measurements, and results of the uranium holdup on the two furnaces.
Salaymeh, S.R.
Thermal casting process for the preparation of anisotropic membranes and the resultant membrane
A method for providing anisotropic polymer membranes from a binary polymer/solvent solution using a thermal inversion process. A homogeneous binary solution is cast onto a support and cooled in such a way as to provide a differential in cooling rate across the thickness of the resulting membrane sheet. Isotropic or anisotropic structures of selected porosities can be produced, depending on the initial concentration of polymer in the selected solvent and on the extent of the differential in cooling rate. This differential results in a corresponding gradation in pore size. The method may be modified to provide a working skin by applying a rapid, high-temperature pulse to redissolve a predetermined thickness of the membrane at one of its faces and then freezing the entire structure.
Caneba, Gerard T. M. (Albany, CA); Soong, David S. (Albany, CA)
Prevention of Porosity Formation and Other Effects of Gaseous Elements in Iron Castings
Iron foundries have observed porosity primarily as interdendritic porosity in large freezing range alloys such as Ni-Hard I and hypoeutectic high Cr alloys or pinholes and fissure defects in gray and ductile irons. For most iron foundries, porosity problems occur sporadically, but even occasional outbreaks can be costly since even a very small amount of porosity can significantly reduce the mechanical properties of the castings. As a result when porosity is detected, the castings are scrapped and remelted, or when the porosity is undetected, defective parts are shipped to the consumer. Neither case is desirable. This project was designed to examine various factors contributing to the porosity formation in iron castings. Factors such as solubility of gases in liquid and solid iron alloys, surface tension of liquid iron alloys, and permeability of dendritic structures were investigated in terms of their effect on the porosity formation. A method was developed to predict how much nitrogen the molten alloy picks up from air after a given amount of holding time for a given melting practice. It was shown that small batches of iron melts in an induction furnace can end up with very high concentration of nitrogen (near solubility limit). Surface tension of liquid iron alloys was measured as a function of temperature. Effect of minor additions of S, Ti, and Al on the surface tension of liquid iron alloys was investigated. Up to 18% change in surface tension was detected by minor element additions. This translates to the same amount of change in gas pressure required in a bubble of a given size to keep the bubble stable. A new method was developed to measure the permeability of dendritic structures in situ. The innovative aspect of these experiments, with respect to previous interdendritic permeability measurements, was the fact that the dendritic structure was allowed to form in situ and was not cooled and re-heated for permeability tests. A permeability model was developed and tested using the results of the permeability experiments. The permeability model for flow parallel to the columnar dendrites predicted the experimental permeability results closely when the liquid volume fraction data from equilibrium calculations were used. The permeability gradient model was constructed in order to test the impact of interdendritic channel constriction on the flow of liquid through the mushy zone of a casting. The model examines two different regimes: (i) Dendritic solidification regime where the permeability is dominated by changes in liquid volume fraction and dendrite arm spacing, and (ii) Eutectic solidification regime where the permeability is dominated by changes in viscosity of eutectic mixture. It is assumed that the eutectic mixture behaves like a slurry whose viscosity increases with increasing solid fraction. It is envisioned that this model can be developed into a tool that can be very useful for metal casters.
Albany Research Center
Microstructural characterization of as-cast biocompatible Co-Cr-Mo alloys
The microstructure of a cobalt-base alloy (Co-Cr-Mo) obtained by the investment casting process was studied. This alloy complies with the ASTM F75 standard and is widely used in the manufacturing of orthopedic implants because of its high strength, good corrosion resistance and excellent biocompatibility properties. This work focuses on the resulting microstructures arising from samples poured under industrial environment conditions, of three different Co-Cr-Mo alloys. For this purpose, we used: 1) an alloy built up from commercial purity constituents, 2) a remelted alloy and 3) a certified alloy for comparison. The characterization of the samples was achieved by using optical microscopy (OM) with a colorant etchant to identify the present phases and scanning electron microscopy (SE-SEM) and energy dispersion spectrometry (EDS) techniques for a better identification. In general the as-cast microstructure is a Co-fcc dendritic matrix with the presence of a secondary phase, such as the M{sub 23}C{sub 6} carbides precipitated at grain boundaries and interdendritic zones. These precipitates are the main strengthening mechanism in this type of alloys. Other minority phases were also reported and their presence could be linked to the cooling rate and the manufacturing process variables and environment. - Research Highlights: {yields}The solidification microstructure of an ASTM-F75 type alloy were studied. {yields}The alloys were poured under an industrial environment. {yields}Carbides and sigma phase identified by color metallography and scanning microscopy (SEM and EDS). {yields}Two carbide morphologies were detected 'blocky type' and 'pearlite type'. {yields}Minority phases were also detected.
Giacchi, J.V., E-mail: firstname.lastname@example.com [Consejo Nacional de Investigaciones Cientificas y Tecnicas (CONICET), Av. Rivadavia 1917, C1033AAJ Buenos Aires (Argentina); Instituto de Fisica de Materiales Tandil (IFIMAT-FCE-CICPBA) Facultad de Ciencias Exactas, Universidad Nacional del Centro de la Provincia de Buenos Aires, Pinto 399 B7000GHG Tandil (Argentina); Morando, C.N.; Fornaro, O. [Consejo Nacional de Investigaciones Cientificas y Tecnicas (CONICET), Av. Rivadavia 1917, C1033AAJ Buenos Aires (Argentina); Instituto de Fisica de Materiales Tandil (IFIMAT-FCE-CICPBA) Facultad de Ciencias Exactas, Universidad Nacional del Centro de la Provincia de Buenos Aires, Pinto 399 B7000GHG Tandil (Argentina); Palacio, H.A. [Comision de Investigaciones Cientificas de la Provincia de Buenos Aires (CICPBA), Calle 526 e/10 y 11 B1096APP La Plata (Argentina); Instituto de Fisica de Materiales Tandil (IFIMAT-FCE-CICPBA) Facultad de Ciencias Exactas, Universidad Nacional del Centro de la Provincia de Buenos Aires, Pinto 399 B7000GHG Tandil (Argentina)
Utilities in the U.S. operate over 75,000 km (47,000 miles) of old cast-iron pipes for gas distribution. The bell-and-spigot joints that connect pipe sections together tend to leak as these pipes age. Current repair practices are costly and highly disruptive. The objective of this program is to design, test and commercialize a robotic system capable of sealing multiple castiron bell and spigot joints from a single pipe entry point. The proposed system will perform repairs while the pipe remains in service by traveling through the pipe, cleaning each joint surface, and installing a stainless-steel sleeve lined with an epoxy-impregnated felt across the joint. This approach will save considerable time and labor, avoid traffic disruption, and eliminate any requirement to interrupt service to customers (which would result in enormous expense to utilities). Technical challenges include: (1) repair sleeves must compensate for diametric variation and eccentricity of cast-iron pipes; (2) the assembly must travel long distances through pipes containing debris; (3) the pipe wall must be effectively cleaned in the immediate area of the joint to assure good bonding of the sleeve; and (4) an innovative bolt-on entry fitting is required to conduct repair operations on live mains. The development effort is divided into eleven tasks. Task 1 (Program Management) and Task 2 (Establishment of Detailed Design Specifications) were completed in prior quarters while Task 3 (Design and Fabricate Ratcheting Stainless-Steel Repair Sleeves) has progressed to installing prototype sleeves in cast iron test pipe segments. Efforts in this quarter continued to focus on Tasks 4-8, with significant progress made in each as well as field testing of the 4-inch gas pipe repair robot in cast iron pipe at Public Service Electric & Gas. The field tests were conducted August 23-26, 2004 in Oradell, New Jersey. The field tests identified several design issues which need to be implemented in both the small- and large-diameter cast iron repair robots to assure their commercial success. Task 4 (Design, Fabricate and Test Patch Setting Robotic Train) progressed to the design of the control electronics and pneumatic system to inflate the bladder robotic patch setting module in the last quarter 5. In this quarter, work has been concentrated on increasing the nitrogen bladder reservoir volume to allow at least two complete patch inflation/patch setting cycles in the event the sleeve does not set all ratchets in the same row on the first attempt. This problem was observed on a few of the repair sleeves that were recently installed during field tests with the small-diameter robotic system. For Task 5 (Design & Fabricate Pipe-Wall Cleaning Robot Train with Pan/Zoom/Tilt Camera) it was observed that it will be necessary to add a stiff brush to push debris away from the immediate vicinity of the bell and spigot joints in mains having low gas velocities. Otherwise, material removed by the cleaning flails (which were found to be very effective in cleaning bell and spigot joints) simply falls to the low side of the pipe and accumulates in a pile. This accumulation can prevent the sleeve from achieving a leak free repair. Similarly, it is also necessary to design a small magnet to capture existing service tap coupons and allow their removal from the inside of the pipe. These coupons were found to cause difficulty in launching and retrieving the small pipe repair robot; one coupon lodged beneath the end of the guide shoe. These new features require redesign of the pipe wall cleaning train and modification to the patch setting train. Task 6 (Design & Build Surface Control and Monitoring System) was previously completed with the control and computer display functions being operated through LabView. However, this must now be re-visited to add control routines for the coupon catcher to be added. This will most likely include a lift-off/place-on magnet translation function. Task 7 (Design & Fabricate Large Diameter Live Access System) progressed to completing the detailed design of th
Subcriticality Measurements with HEU (93.2) Metal Annular Storage Castings
These carefully performed and documented measurements with unreflected and unmoderated highly enriched uranium (HEU) castings can be used to benchmark calculational methods for the time decay of the fission chain multiplication process as measured with small (1 x 1 x 6 in. thick plastic scintillators with 1/4-in.-thick lead on all detector surfaces) detectors adjacent to the tightly fitting stainless steel cans that contained the HEU ({approx}93 wt%) metal. Prompt time decay measurements were performed stimulating the fission chain multiplication process with a timed, tagged Cf spontaneous fission source that emitted fission-spectrum neutrons and a time and directionally tagged 14.1-MeV neutrons from the DT reaction in a steady state generator with an embedded alpha detector. Time decay measurements were performed with HEU masses varying from 18 to 90 kg for a wide variety of source-detector-casting configurations. The use of a DT generator provided no addition information about the fission chain behavior beyond that provided by a time-tagged Cf spontaneous fission source. The main quantities obtained in the measurements were (1) the time distribution of the counts in a detector after a neutron fission in the Cf source or after the alpha detection coincident with the emission of a neutron from the DT generator (the equivalent of a pulsed neutron measurement with a randomly pulsed source) and (2) the time distribution of counts in one detector after a count in another detector (the equivalent of a two-detector Rossi-alpha measurement). Monte Carlo calculations using the MCNP-PoliMi coupled gamma-neutron transport code generally agreed with the measurement results except for some differences early in the fission chain decay process. The measurements that were performed with the HEU about 1 m above the floor were considerably affected by room return neutrons at times as early as 100 ns, and at times after 300 ns, a major portion of the time response was associated with the interaction of the HEU assemblies with the floor. This room-return effect increased with the size of the assembly because the larger assemblies subtend a larger solid angle to a neutron returning from the floor.
Henkel, James J [ORNL; Wright, Michael C [ORNL; Archer, Daniel E [ORNL; Mullens, James Allen [ORNL; Mihalczo, John T [ORNL
Grain refinement of cast niobium via equal channel angular extrusion/annealing
This research investigated the effectiveness of equal channel angular extrusion (ECAE) and annealing to improve the grain morphology and mechanical properties of electron-beam remelted pure niobium. Extrusions were performed at room temperature with a 90o die. Routes 1A, 2C, 4E and 8E were investigated with duplicate billets undergoing routes 1A, 2C and 4E to determine reproducibility. Niobium proved to be very workable during the ECAE process. Hardness increased most dramatically after the first pass and leveled off thereafter. Recrystallization temperatures for the Reference Metals material ranged from a low of 800o C for routes 2C, 4E and 8E to a high of 1000o C for route 1A. For the Wah Chang material, the recrystallization temperatures ranged from a low of 800o C for the 4E ECAE processed material to a high of 950o C for the asreceived material. The initial grain size and orientation have been hypothesized to be influential on recrystallized grain morphology for ECAE/annealing processed niobium. Smaller initial grains produce a smaller and more homogeneous recrystallized grain microstructure. The average grain diameters for the recrystallized 4E ECAE processed Wah Chang material are 13 �?± 6.3 mm for the 1000o C annealed state (no banding) and are 21 �?± 9.5 mm for the 1100o C annealed state (no banding). Reference Metals material that underwent route 4E and annealed at 1000o C resulted in an average grain diameter of 28 mm for billet 2 (banding) and an average grain diameter of 32 mm for billet 19 (slight banding). Reference Metals material that underwent route 8E (no banding) annealed at 1000o C resulted in an average grain diameter of 36 mm. Reference Metals material that underwent route 4E samples annealed at 1100o C resulted in an average grain diameter of 26 mm for billet 2 (banding) and an average grain diameter of 43 mm for billet 19 (slight banding). Route 8E (significant banding) annealed at 1100o C resulted in an average grain diameter of 29 mm. Strain failure decreases from the as-cast material to the worked/recrystallized material while the 0.2% yield stress and ultimate tensile strength increase from the as-cast material to the worked/recrystallized material. Long sub-grains are created in the as-worked material after one and two passes and become more broken up after four passes. Sub-grain boundary angles increase with increasing strain. To produce a fine and homogeneous microstructure from large grained niobium, intermediate annealing should be employed.
Bryant, Don O.
Atomistic modeling of nanowires, small-scale fatigue damage in cast magnesium, and materials for MEMS.
Lightweight and miniaturized weapon systems are driving the use of new materials in design such as microscale materials and ultra low-density metallic materials. Reliable design of future weapon components and systems demands a thorough understanding of the deformation modes in these materials that comprise the components and a robust methodology to predict their performance during service or storage. Traditional continuum models of material deformation and failure are not easily extended to these new materials unless microstructural characteristics are included in the formulation. For example, in LIGA Ni and Al-Si thin films, the physical size is on the order of microns, a scale approaching key microstructural features. For a new potential structural material, cast Mg offers a high stiffness-to-weight ratio, but the microstructural heterogeneity at various scales requires a structure-property continuum model. Processes occurring at the nanoscale and microscale develop certain structures that drive material behavior. The objective of the work presented in this report was to understand material characteristics in relation to mechanical properties at the nanoscale and microscale in these promising new material systems. Research was conducted primarily at the University of Colorado at Boulder to employ tightly coupled experimentation and simulation to study damage at various material size scales under monotonic and cyclic loading conditions. Experimental characterization of nano/micro damage will be accomplished by novel techniques such as in-situ environmental scanning electron microscopy (ESEM), 1 MeV transmission electron microscopy (TEM), and atomic force microscopy (AFM). New simulations to support experimental efforts will include modified embedded atom method (MEAM) atomistic simulations at the nanoscale and single crystal micromechanical finite element simulations. This report summarizes the major research and development accomplishments for the LDRD project titled 'Atomistic Modeling of Nanowires, Small-scale Fatigue Damage in Cast Magnesium, and Materials for MEMS'. This project supported a strategic partnership between Sandia National Laboratories and the University of Colorado at Boulder by providing funding for the lead author, Ken Gall, and his students, while he was a member of the University of Colorado faculty.
Dunn, Martin L. (University of Colorado, Boulder, CO); Talmage, Mellisa J. (University of Colorado, Boulder, CO); McDowell, David L., 1956- (,-Georgia Institute of Technology, Atlanta, GA); West, Neil (University of Colorado, Boulder, CO); Gullett, Philip Michael (Mississippi State University , MS); Miller, David C. (University of Colorado, Boulder, CO); Spark, Kevin (University of Colorado, Boulder, CO); Diao, Jiankuai (University of Colorado, Boulder, CO); Horstemeyer, Mark F. (Mississippi State University , MS); Zimmerman, Jonathan A.; Gall, K (Georgia Institute of Technology, Atlanta, GA)
Energy Saving Melting and Revert Reduction Technology: Improved Die Casting Process to Preserve the Life of the Inserts
The goal of this project was to study the combined effects of die design, proper internal cooling and efficient die lubricants on die life. The project targeted improvements in die casting insert life by: Optomized Die Design for Reduced Surface Temperature: The life of die casting dies is significantly shorter when the die is exposed to elevated temperature for significant periods of time. Any die operated under conditions leading to surface temperature in excess of 1050oF undergoes structural changes that reduce its strength. Optimized die design can improve die life significantly. This improvement can be accomplished by means of cooling lines, baffles and bubblers in the die. A key objective of the project was to establish criteria for the minimal distance of the cooling lines from the surface. This effort was supported with alloys and machining by BohlerUddeholm, Dunn Steel, HH Stark and Rex Buckeye. In plant testing and evaluation was conducted as in-kind cost share at St. Clair Die Casting. The Uddeholm Dievar steel evaluated in this program showed superior resistance to thermal fatigue resistance. Based on the experimental evidence, cooling lines could be placed as close as 0.5" from the surface. Die Life Extension by Optimized Die Lubrication: The life of die casting dies is affected by additions made to its surface with the proper lubricants. These lubricants will protect the surface from the considerable temperature peaks that occur when the molten melt enters the die. Dies will reach a significantly higher temperature without this lubricant being applied. The amount and type of the lubricant are critical variables in the die casting process. However, these lubricants must not corrode the die surface. This effort was supported with alloys and machining by BohlerUddeholm, Dunn Steel, HH Stark and Rex Buckeye. In plant testing and evaluation was conducted as in-kind cost share at St. Clair Die Casting. Chem- Trend participated in the program with die lubricants and technical support. Experiments conducted with these lubricants demonstrated good protection of the substrate steel. Graphite and boron nitride used as benchmarks are capable of completely eliminating soldering and washout. However, because of cost and environmental considerations these materials are not widely used in industry. The best water-based die lubricants evaluated in this program were capable of providing similar protection from soldering and washout. In addition to improved part quality and higher production rates, improving die casting processes to preserve the life of the inserts will result in energy savings and a reduction in environmental wastes. Improving die life by means of optimized cooling line placement, baffles and bubblers in the die will allow for reduced die temperatures during processing, saving energy associated with production. The utilization of optimized die lubricants will also reduce heat requirements in addition to reducing waste associated with soldering and washout. This new technology was predicted to result in an average energy savings of 1.1 trillion BTU's/year over a 10 year period. Current (2012) annual energy saving estimates, based on commercial introduction in 2010, a market penetration of 70% by 2020 is 1.26 trillion BTU's/year. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology. The average annual estimate of CO2 reduction per year through 2020 is 0.025 Million Metric Tons of Carbon Equivalent (MM TCE).
David Schwam, PI; Xuejun Zhu, Sr. Research Associate
Development of Stronger and More Reliable Cast Austenitic Stainless Steels (H-Series) Based on Scientific and Design Methodology
The goal of this project was to increase the high-temperature strength of the H-Series of cast austenitic stainless steels by 50% and the upper use temperature by 86 to 140 degrees fahrenheit (30 to 60 degrees celsius). Meeting this goal is expected to result in energy savings of 35 trillion Btu/year by 2020 and energy cost savings of approximately $230 million/year. The higher-strength H-Series cast stainless steels (HK and HP type) have applications for the production of ethylene in the chemical industry, for radiant burner tubes and transfer rolls for secondary processing of steel in the steel industry, and for many applications in the heat treating industry, including radiant burner tubes. The project was led by Duraloy Technologies, Inc., with research participation by Oak Ridge National Laboratory (ORNL) and industrial participation by a diverse group of companies.
Pankiw, Roman I; Muralidharan, G. (Murali); Sikka, Vinod K.
An evaluation of joint repair methods for cast iron natural gas distribution mains and the preliminary development of an alternative joint seal
Approximately 10 percent of the natural gas pumped into distribution systems is unaccounted for. A significant portion of this amount is leakage from joints in 50 to 100 year old cast iron main. Because of the cumulative ...
Rogers, Thomas Edward
Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Annual subcontract report, January 1, 1995--December 31, 1995
The objective of this three-year program is to advance Solarex`s cast polycrystalline silicon manufacturing technology, reduce module production cost, increase module performance and expand Solarex`s commercial production capacities. Two specific objectives of this program are to reduce the manufacturing cost for polycrystalline silicon PV modules to less than $1.20/watt and to increase the manufacturing capacity by a factor of three.
Wohlgemuth, J. [Amoco/Enron Solar, Frederick, MD (United States)
Thermal energy storage using Prestressed Cast Iron Vessels (PCIV). Final report
The wide-spread application of thermal energy and high-pressure air storage to electric power generation has so far been hampered by the lack of large high-pressure storage vessels of reasonable cost. Welded steel vessels are too expensive for this purpose. However, the Prestressed Cast Iron Vessel (PCIV), developed as a nuclear reactor pressure vessel by Siempelkamp Giesserei KG of Krefeld, FRG, has the potential of complying with these requirements. Applications of the PCIV include: high-pressure air storage for the quick start-up of open cycle gas turbines; pressurized high-temperature sensible heat storage by means of solids with a gaseous heat transfer medium for closed cycle gas turbines of future solar power stations; and pressurized hot water storage for nuclear, solar, or coal-fired steam power plants, employing either separate peaking turbines or overloadable main turbine sets. A reference PCIV of 8000 m/sup 3/, 275/sup 0/C, with hot going walls and cold going tendons was developed, designed, and stress-analysed. A parametric study showed that pressures between 4 and 8 MPa and L/D ratios larger than 4 should be optimal. Cost of the reference vessel is about $10,000,000 or 33 to 50 $/kWh electric energy stored. Cost of peak power will be from 30 to 100 mills/kWh, depending on many parameters.
Gilli, P.V.; Beckmann, G.; Schilling, F.E.
Modeling of material and energy flow in an EBCHR casting system
A numerical and experimental analysis is made of fluid flow and heat transfer in a continuous casting system with an electron-beam energy source. For a cylindrical ingot confined in a water-cooled crucible, a two-dimensional, steady-state model is developed which includes the effects of free convection in the pool and conduction in the two-phase and solid regions. A modified Galerkin finite element method is used to solve for the flow and temperature fields simultaneously with the upper and lower boundaries of the pool. The calculation grid deforms along vertical spines as these phase boundaries move. Heat flows are measured in a steady-state experiment involving a short ingot and no pouring. Heat transfer coefficients representing contact resistance are determined, and measured heat flows are compared with model values. Flow and temperature fields along with solidification-zone boundaries are calculated for the experimental case and a case in which the ingot cooling is improved.
Westerberg, K.W. [Aspen Technology, Inc., Cambridge, MA (United States); McClelland, M.A. [Lawrence Livermore National Lab., CA (United States)
CAST search for sub-eV mass solar axions with 3He buffer gas
The CERN Axion Solar Telescope (CAST) has extended its search for solar axions by using 3He as a buffer gas. At T=1.8 K this allows for larger pressure settings and hence sensitivity to higher axion masses than our previous measurements with 4He. With about 1 h of data taking at each of 252 different pressure settings we have scanned the axion mass range 0.39 eV < m_a < 0.64 eV. From the absence of excess X-rays when the magnet was pointing to the Sun we set a typical upper limit on the axion-photon coupling of g_ag < 2.3 x 10^{-10} GeV^{-1} at 95% CL, the exact value depending on the pressure setting. KSVZ axions are excluded at the upper end of our mass range, the first time ever for any solar axion search. In future we will extend our search to m_a < 1.15 eV, comfortably overlapping with cosmological hot dark matter bounds.
M. Arik; S. Aune; K. Barth; A. Belov; S. Borghi; H. Br�uninger; G. Cantatore; J. M. Carmona; S. A. Cetin; J. I. Collar; T. Dafni; M. Davenport; C. Eleftheriadis; N. Elias; C. Ezer; G. Fanourakis; E. Ferrer-Ribas; P. Friedrich; J. Gal�n; J. A. Garc�a; A. Gardikiotis; E. N. Gazis; T. Geralis; I. Giomataris; S. Gninenko; H. G�mez; E. Gruber; T. Guth�rl; R. Hartmann; F. Haug; M. D. Hasinoff; D. H. H. Hoffmann; F. J. Iguaz; I. G. Irastorza; J. Jacoby; K. Jakov?i?; M. Karuza; K. K�nigsmann; R. Kotthaus; M. Kr?mar; M. Kuster; B. Laki?; J. M. Laurent; A. Liolios; A. Ljubi?i?; V. Lozza; G. Lutz; G. Luz�n; J. Morales; T. Niinikoski; A. Nordt; T. Papaevangelou; M. J. Pivovaroff; G. Raffelt; T. Rashba; H. Riege; A. Rodr�guez; M. Rosu; J. Ruz; I. Savvidis; P. S. Silva; S. K. Solanki; L. Stewart; A. Tom�s; M. Tsagri; K. van Bibber; T. Vafeiadis; J. Villar; J. K. Vogel; S. C. Yildiz; K. Zioutas
Mechanical-property degradation of cast stainless steel components from the Shippingport reactor
The mechanical properties of cast stainless steels from the Shippingport reactor have been characterized. Baseline properties for unaged materials were obtained from tests on either recovery-annealed material or material from a cooler region of the component. The materials exhibited modest decrease in impact energy and fracture toughness and a small increase in tensile strength. The fracture toughness J-R curve, J{sub IC} value, tensile flow stress, and Charpy-impact energy of the materials showed very good agreement with estimations based on accelerated laboratory aging studies. The kinetics of thermal embrittlement and degree of embrittlement at saturation, i.e., the minimum impact energy that would be achieved after long-term aging, were established from materials that were aged further in the laboratory at temperatures between 320 and 400{degrees}C. The results showed very good agreement with estimates; the activation energies ranged from 125 to 250 kJ/mole and the minimum room temperature impact energy was <75 J/cm{sup 2}. The estimated impact energy and fracture toughness J-R curve for materials from the Ringhals reactor hot and crossover-leg elbows are also presented.
Chopra, O.K.
Welding and mechanical properties of cast FAPY (Fe-16 at. % Al-based) alloy slabs
This report deals with the welding procedure development and weldment properties of an Fe-16 at. % Al alloy known as FAPY. The welding procedure development was carried out on 12-, 25-, and 51-mm (0.5-, 1-, and 2-in.) -thick plates of the alloy in the as-cast condition. The welds were prepared by using the gas tungsten arc process and filler wire of composition matching the base-metal composition. The preheat temperatures varied from room temperature to 350{degrees}C, and the postweld heat treatment (PWHT) was limited only for 1 h at 750{degrees}C. The welds were characterized by microstructural. analysis and microhardness data. The weldment specimens were machined for Charpy-impact, tensile, and creep properties. The tensile and creep properties of the weldment specimens were essentially the same as that of the base metal. The Charpy-impact properties of the weldment specimens improved with the PWHT and were somewhat lower than previously developed data on the wrought material. Additional work is required on welding of thicker sections, development of PWHT temperatures as a function of section thickness, and mechanical properties.
Sikka, V.K.; Goodwin, G.M.; Alexander, D.J.; Howell, C.R.
Waste minimization assessment for a manufacturer of iron castings and fabricated sheet metal parts
The U.S. Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-size manufacturers who want to minimize their generation of waste but who lack the expertise to do so. Waste Minimization Assessment Centers (WMACs) were established at selected universities and procedures were adapted from the EPA Waste Minimization Opportunity Assessment Manual. That document has been superseded by the Facility Pollution Prevention Guide. The WMAC team at the University of Louisville performed an assessment at a plant that manufactures iron castings and fabricated sheet metal parts. Foundry operations include mixing and mold formation, core making, metal pouring, shakeout, finishing, and painting. Cutting, shaping, and welding are the principal metal fabrication operations. The team`s report, detailing findings and recommendations indicated that paint-related wastes are generated in large quantities, and that significant waste reduction and cost savings could be realized by installing a dry powder coating system or by replacing conventional air spray paint guns with high-volume low-pressure spray guns. This research brief was developed by the principal investigators and EPA`s National Risk Management Research Laboratory, Cincinnati, OH, to announce key findings of an ongoing research project that is fully documented in a separate report of the same title available from University City Science Center.
Fleischman, M.; Harris, J.J.; Handmaker, A.; Looby, G.P.
The Influence of VIM Crucible Composition, Vacuum Arc Remelting ...
ing a weight of 23 kilograms. (50 pounds). The as-cast ingot surface was maintained on all ingots. VIM Ingot Cleanliness. Evaluation. The cleanliness evaluation.
The Effect of Applied Pressure During Feeding of Critical Cast Aluminum Alloy Components With Particular Reference to Fatigue Resistance
the medium to long freezing range alloys of aluminum such as A356, A357, A206, 319 for example are known to exhibit dispersed porosity, which is recognized as a factor affecting ductility, fracture toughness, and fatigue resistance of light alloy castings. The local thermal environment, for example, temperature gradient and freezing from velocity, affect the mode of solidification which, along with alloy composition, heat treatment, oxide film occlusion, hydrogen content, and the extent to which the alloy contracts on solidification, combine to exert strong effects on the porosity formation in such alloys. In addition to such factors, the availability of liquid metal and its ability to flow through the partially solidified casting, which will be affect by the pressure in the liquid metal, must also be considered. The supply of molten metal will thus be controlled by the volume of the riser available for feeding the particular casting location, its solidification time, and its location together with any external pressure that might be applied at the riser.
J.T. Berry; R. Luck; B. Zhang; R.P. Taylor
The elevated-temperature mechanical behavior of as-cast and wrought Ti-6Al-4V-1B
This work studied the effect of processing on the elevated-temperature [728 K (455 C)] fatigue deformation behavior of Ti-6Al-4V-1B for maximum applied stresses between 300 to 700 MPa (R = 0.1, 5 Hz). The alloy was evaluated in the as-cast form as well as in three wrought forms: cast-and-extruded, powder metallurgy (PM) rolled, and PM extruded. Processing caused significant differences in the microstructure, which in turn impacted the fatigue properties. The PM-extruded material exhibited a fine equiaxed {alpha} + {beta} microstructure and the greatest fatigue resistance among all the studied materials. The {beta}-phase field extrusion followed by cooling resulted in a strong {alpha}-phase texture in which the basal plane was predominately oriented perpendicular to the extrusion axis. The TiB whiskers were also aligned in the extrusion direction. The {alpha}-phase texture in the extrusions resulted in tensile-strength anisotropy. The tensile strength in the transverse orientation was lower than that in the longitudinal orientation, but the strength in the transverse orientation remained greater than that for the as-cast Ti-6Al-4V. The ratcheting behavior during fatigue is also discussed.
Chen, Wei [ORNL; Boehlert, C. J. [Michigan State University, East Lansing; Howe, Jane Y [ORNL; Payzant, E Andrew [ORNL
Impact evaluation of an induction furnace replacement under the Energy $avings Plan at Mackenzie Specialty Castings, Incorporated
This impact evaluation of an induction furnace replacement that was recently installed at Mackenzie Specialty Castings, Incorporated (Mackenzie Castings) was conducted for the Bonneville Power Administration (Bonneville) as part of an evaluation of its Energy Savings Plan (ESP) Program. The project consists of replacing old power supplies and induction furnace with new, more efficient supplies and equipment. The objective of this impact evaluation was to assess how much electrical energy is being saved at Mackenzie Castings as a result of the ESP and to determine how much the savings cost Bonneville and the region. The impact of the project was evaluated with a combination of engineering analysis, financial analysis, interviews, and submittal reviews (Mackenzie Castings`s proposal and completion report). Based on this impact evaluation, energy savings from this project are expected to be 425,257 kWh/yr at minimum annual production, 647,037 kWh/yr at typical annual production, and 1,294,074 kWh/yr at maximum annual production, or 0.05, 0.07, and 0.15 average megawatts, respectively. On a per-ton basis, this project will save 608 kWh/ton or 31% at minimum production and 431 kWh/ton or 39% at typical and maximum production. The project cost $277,110 to install, and Mackenzie Castings received payment of $102,551 (in 1993 dollars) from Bonneville for acquisition of the energy savings. The real levelized cost of these energy savings to Bonneville is 22.9 mills/kWh at minimum production, 15.1 mills/kWh typical production, and 7.5 mills/kWh at maximum production (in 1993 dollars) over the project`s assumed 15-year life. The real levelized cost to the region is 59.1 mills/kWh at minimum production, 38.8 mills/kWh at typical production, and 19.4 mills/kWh at maximum production in 1993 dollars, not including transmission and distribution effects.
Oens, M.A.; Spanner, G.E.
Waste Acceptance Testing of Secondary Waste Forms: Cast Stone, Ceramicrete and DuraLith
To support the selection of a waste form for the liquid secondary wastes from WTP, Washington River Protection Solutions has initiated secondary-waste-form testing work at Pacific Northwest National Laboratory (PNNL). In anticipation of a down-selection process for a waste form for the Solidification Treatment Unit to be added to the ETF, PNNL is conducting tests on four candidate waste forms to evaluate their ability to meet potential waste acceptance criteria for immobilized secondary wastes that would be placed in the IDF. All three waste forms demonstrated compressive strengths above the minimum 3.45 MPa (500 psi) set as a target for cement-based waste forms. Further, none of the waste forms showed any significant degradation in compressive strength after undergoing thermal cycling (30 cycles in a 10 day period) between -40 C and 60 C or water immersion for 90 days. The three leach test methods are intended to measure the diffusion rates of contaminants from the waste forms. Results are reported in terms of diffusion coefficients and a leachability index (LI) calculated based on the diffusion coefficients. A smaller diffusion coefficient and a larger LI are desired. The NRC, in its Waste Form Technical Position (NRC 1991), provides recommendations and guidance regarding methods to demonstrate waste stability for land disposal of radioactive waste. Included is a recommendation to conduct leach tests using the ANS 16.1 method. The resulting leachability index (LI) should be greater than 6.0. For Hanford secondary wastes, the LI > 6.0 criterion applies to sodium leached from the waste form. For technetium and iodine, higher targets of LI > 9 for Tc and LI > 11 for iodine have been set based on early waste-disposal risk and performance assessment analyses. The results of these three leach tests conducted for a total time between 11days (ASTM C1308) to 90 days (ANS 16.1) showed: (1) Technetium diffusivity: ANSI/ANS 16.1, ASTM C1308, and EPA 1315 tests indicated that all the waste forms had leachability indices better than the target LI > 9 for technetium; (2) Rhenium diffusivity: Cast Stone 2M specimens, when tested using EPA 1315 protocol, had leachability indices better than the target LI > 9 for technetium based on rhenium as a surrogate for technetium. All other waste forms tested by ANSI/ANS 16.1, ASTM C1308, and EPA 1315 test methods had leachability indices that were below the target LI > 9 for Tc based on rhenium release. These studies indicated that use of Re(VII) as a surrogate for 99Tc(VII) in low temperature secondary waste forms containing reductants will provide overestimated diffusivity values for 99Tc. Therefore, it is not appropriate to use Re as a surrogate 99Tc in future low temperature waste form studies. (3) Iodine diffusivity: ANSI/ANS 16.1, ASTM C1308, and EPA 1315 tests indicated that the three waste forms had leachability indices that were below the target LI > 11 for iodine. Therefore, it may be necessary to use a more effective sequestering material than silver zeolite used in two of the waste forms (Ceramicrete and DuraLith); (4) Sodium diffusivity: All the waste form specimens tested by the three leach methods (ANSI/ANS 16.1, ASTM C1308, and EPA 1315) exceeded the target LI value of 6; (5) All three leach methods (ANS 16.1, ASTM C1308 and EPA 1315) provided similar 99Tc diffusivity values for both short-time transient diffusivity effects as well as long-term ({approx}90 days) steady diffusivity from each of the three tested waste forms (Cast Stone 2M, Ceramicrete and DuraLith). Therefore, any one of the three methods can be used to determine the contaminant diffusivities from a selected waste form.
Mattigod, Shas V.; Westsik, Joseph H.; Chung, Chul-Woo; Lindberg, Michael J.; Parker, Kent E.
Textures in Strip-Cast Aluminum Alloys: Their On-Line Monitoring and Quantitative Effects on Formability. Final Technical Report
Aluminum sheets produced by continuous casting (CC) provide energy and economic savings of at least 25 and 14 percent, respectively, over sheets made from conventional direct chill (DC) ingot casting and rolling. As a result of the much simpler production route in continuous casting, however, the formability of CC aluminum alloys is often somewhat inferior to that of their DC counterparts. The mechanical properties of CC alloys can be improved by controlling their microstructure through optimal thermomechanical processing. Suitable annealing is an important means to improve the formability of CC aluminum alloy sheets. Recrystallization of deformed grains occurs during annealing, and it changes the crystallographic texture of the aluminum sheet. Laboratory tests in this project showed that this texture change can be detected by either laser-ultrasound resonance spectroscopy or resonance EMAT (electromagnetic acoustic transducer) spectroscopy, and that monitoring this change allows the degree of recrystallization or the ''recrystallized fraction'' in an annealed sheet to be ascertained. Through a plant trial conducted in May 2002, this project further demonstrated that it is feasible to monitor the recrystallized state of a continuous-cast aluminum sheet in-situ on the production line by using a laser-ultrasound sensor. When used in conjunction with inline annealing, inline monitoring of the recrystallized fraction by laser-ultrasound resonance spectroscopy offers the possibility of feed-back control that helps optimize processing parameters (e.g., annealing temperature), detect production anomalies, ensure product quality, and further reduce production costs of continuous-cast aluminum alloys. Crystallographic texture strongly affects the mechanical anisotropy/formability of metallic sheets. Clarification of the quantitative relationship between texture and anisotropy/formability of an aluminum alloy will render monitoring and control of its texture during the sheet production process even more meaningful. The present project included a study to determine how the anisotropic plastic behavior of a continuous-cast AA 5754 aluminum alloy depends on quantifiable texture coefficients. Formulae which show explicitly the effects of texture on the directional dependence of the q-value (a formability parameter) and of the uniaxial flow stress, respectively, were derived. Measurements made on a batch of as-received AA 5754 hot band and its O-temper counterpart corroborate the validity of these formulae. On the other hand, these measurements also indicate that some microstructure(s) other than texture could play a significant role in the plastic anisotropy of the AA 5754 alloy. For the q-value of a set of O-temper samples of this alloy, the additional microstructure that affects plastic anisotropy was shown to be grain shape. A formula that captures both the effects of crystallographic texture and grain shape on the q-value of the O-temper material was derived. A simple quadratic plastic potential that delivers this q-value formula was written down. Verification of the adequacy of this plastic potential, however, requires further investigations.
Man, Chi-Sing
Development of Cost-Effective Low-Permeability Ceramic and Refractory Components for Aluminum Melting and Casting
The primary goal of this project was to develop and validate new classes of cost-effective low-permeability ceramic and refractory components for handling molten aluminum in both melting and casting environments. Three approaches were employed with partial to full success to achieve this goal: (1) Develop materials and methods for sealing surface porosity in thermal-shock-resistant ceramic refractories; (2) Develop new ceramic coatings for extreme service in molten aluminum operations, with particular emphasis on coatings based on highly stable oxide phases; and (3) Develop new monolithic refractories designed for lower-permeability applications using controlled porosity gradients and particle size distributions. The results of the research work and the field tests performed utilizing these three approaches are listed below: (1) It was demonstrated that high-density IR heating could be a tool for altering and sealing the surface porosity of fused silica. However, the process was not very cost-effective. (2) A low-cost glaze composition having a coefficient of thermal expansion (CTE) similar to that of a DFS tube was identified and was successfully tested for its integrity and adherence to DFS. Although the glaze acted as a barrier between the molten aluminum and the DFS, persistent porosity and crazing within the glaze affected its performance during the reactivity tests, thus acting as an obstacle in scaling up production of this glaze. (3) Pyrotek's XL glaze showed great success in improving the life of the DFS tubes. Pyrotek has reported an increasing market demand for the XL-coated DFS tubes, which exhibit useful lifetimes three times better than those of uncoated tubes. (4) A computer model to optimize particle size distribution for reduced permeability was developed and successfully applied to casting formulations. Silica riser tubes produced using these new formulations have been tested in a commercial aluminum casting facility and have been reported to increase the life of the DFS tubes by 700%. (5) If all the DFS riser tubes used in LPD casting of aluminum automotive components are replaced with the better, longer-lasting castable riser tubes, the potential national energy savings is estimated to be 206 billion Btu/year.
Dale E. Brown (Pyrotek); Puja B. Kadolkar (ORNL)
Enhanced heat transfer surface for cast-in-bump-covered cooling surfaces and methods of enhancing heat transfer
An annular turbine shroud separates a hot gas path from a cooling plenum containing a cooling medium. Bumps are cast in the surface on the cooling side of the shroud. A surface coating overlies the cooling side surface of the shroud, including the bumps, and contains cooling enhancement material. The surface area ratio of the cooling side of the shroud with the bumps and coating is in excess of a surface area ratio of the cooling side surface with bumps without the coating to afford increased heat transfer across the element relative to the heat transfer across the element without the coating.
Chiu, Rong-Shi Paul (Glenmont, NY); Hasz, Wayne Charles (Pownal, VT); Johnson, Robert Alan (Simpsonville, SC); Lee, Ching-Pang (Cincinnati, OH); Abuaf, Nesim (Lincoln City, OR)
A Comparison of Creep-Rupture Tested Cast Alloys HR282, IN740 and 263 for Possible Application in Advanced Ultrasupercritical Steam Turbine and Boiler
Cast forms of traditionally wrought Ni-base precipitation-strengthened superalloys are being considered for service in the ultra-supercritical conditions (760�C, 35MPa) of next-generation steam boilers and turbines. After casting and homogenization, these alloys were given heat-treatments typical for each in the wrought condition to develop the gamma-prime phase. Specimens machined from castings were creep-rupture tested in air at 800�C. In their wrought forms, alloy 282 is expected to precipitate M23C6 within grain boundaries, alloy 740 is expected to precipitate several grain boundary phases including M23C6, G Phase, and ? phase, and alloy 263 has M23C6 and MC within its grain boundaries. This presentation will correlate the observed creep-life of these cast alloys with the microstructures developed during creep-rupture tests, with an emphasis on the phase identification and chemistry of precipitated grain boundary phases. The suitability of these cast forms of traditionally wrought alloys for turbine and boiler components will also be discussed.
Jablonski, P D; Evens, N; Yamamoto, Y; Maziasz, P
Heat transfer at the mold-metal interface in permanent mold casting of aluminum alloys project. Quarterly project status report, April 1--June 30, 1998
Extensive progress in development of an HTC (heat transfer coefficient) Evaluator and in the preparation of the experiments at CMI and Amcast have been achieved in the last three months. The interface of the HTC Evaluator has been developed in Visual C++ for the PC platform. It provides a tool to collect and store the published data on heat transfer coefficients in a database for further analysis. It also supports the mathematical model for evaluation of heat transfer coefficients. More than 100 papers related to this project have been cited and most of them have been collected. The preparation of the experiments at CMI is almost completed. A hockey-puck mold has been selected for the experiments for squeeze casting and semi-solid casting. A direct cavity pressure measurement system was purchased from Kistler. The pressure probes and data acquisition software as well as the necessary accessories have been delivered. The instrumented mold modification has been designed and the modifications completed. At Amcast Automotive, a new wheel-like mold for low-pressure permanent mold casting was designed. The CAD file for mold fabrication has been generated. The modeling of the casting has been done. An extensive survey on the ultrasonic gap formation measurement was fulfilled. It is concluded that the ultrasonic probe is capable of measuring a gap under the authors` casting conditions. In the last three months, four project meetings has been organized and held with the industrial partners.
Pehlke, R.D.; Hao, S.W.
Energy Saving Melting and Revert Reduction (E-SMARRT): Optimization of Heat Treatments on Stainless Steel Castings for Improved Corrosion Resistance and Mechanical Properties
It is commonly believed that high alloy steel castings have inferior corrosion resistance to their wrought counterparts as a result of the increased amount of microsegregation remaining in the as-cast structure. Homogenization and dissolution heat treatments are often utilized to reduce or eliminate the residual microsegregation and dissolve the secondary phases. Detailed electron probe microanalysis (EPMA) and light optical microscopy (LOM) were utilized to correlate the amount of homogenization and dissolution present after various thermal treatments with calculated values and with the resultant corrosion resistance of the alloys.The influence of heat treatment time and temperature on the homogenization and dissolution kinetics were investigated using stainless steel alloys CN3MN and CK3MCuN. The influence of heat treatment time and temperature on the impact toughness and corrosion reistance of cast stainless steel alloys CF-3, CF-3M, CF-8, and CF-8M was also investigated.
John N. DuPont; Jeffrey D. Farren; Andrew W. Stockdale; Brett M. Leister
Simple visualization techniques for die casting part and die design. Final report, July 1, 1995--September 30, 1997
The objective of this work was to develop and test die casting design evaluation techniques based on the visualization of geometric data that is related to potential defects of problems. Specifically, thickness information is used to provide insight into potential thermal problems in the part and die. Distance from the gate and a special type of animation of the fill pattern is used to provide an assessment of gate, vent and overflow locations. Techniques have been developed to convert part design information in the form of STL files to a volume-based representation called a voxel model. The use of STL files makes the process CAD system independent. Once in voxel form, methods that were developed in this work are used to identify thick regions in the part, thin regions in the part and/or die, distance from user specified entry locations (gates), and the qualitative depiction of the fill pattern. The methods were tested with a prototype implementation on the UNIX platform. The results of comparisons with numerical simulation and field reported defects were surprisingly good. The fill-related methods were also compared against short-shots and a water analog study using high speed video. The report contains the results of the testing plus detailed background material on the construction of voxel models, the methods used for displaying results, and the computational geometric reasoning methods used to create die casting-related information form the voxel model for display to the user.
Miller, R.A.; Lu, S.C.; Rebello, A.B.
The objective of this work was to develop and test die casting design evaluation techniques based on the visualization of geometric data that is related to potential defects of problems. Specifically, thickness information is used to provide insight into potential thermal problems in the part and die. Distance from the gate and a special type of animation of the fill pattern is used to provide an assessment of gate, vent and overflow locations. Techniques have been developed to convert part design information in the form of STL files to a volume-based representation called a voxel model. The use of STL files makes the process CAD system independent. Once in voxel form, methods that were developed in this work are used to identify thick regions in the part, thin regions in the part and/or die, distance from user specified entry locations (gates), and the qualitative depiction of the fill pattern. The methods were tested with a prototype implementation on the UNIX platform. The results of comparisons with numerical simulation and field reported defects were surprisingly good. The fill-related methods were also compared against short-shots and a water analog study using high speed video. The report contains the results of the testing plus detailed background material on the construction of voxel models, the methods used for displaying results, and the computational geometric reasoning methods used to create die casting-related information from the voxel model for display to the user.
Heat and corrosion resistant cast CN-12 type stainless steel with improved high temperature strength and ductility
A cast stainless steel alloy and articles formed therefrom containing about 0.5 wt. % to about 10 wt. % manganese, 0.02 wt. % to 0.50 wt. % N, and less than 0.15 wt. % sulfur provides high temperature strength both in the matrix and at the grain boundaries without reducing ductility due to cracking along boundaries with continuous or nearly-continuous carbides. Alloys of the present invention also have increased nitrogen solubility thereby enhancing strength at all temperatures because nitride precipitates or nitrogen porosity during casting are not observed. The solubility of nitrogen is dramatically enhanced by the presence of manganese, which also retains or improves the solubility of carbon thereby providing additional solid solution strengthening due to the presence of manganese and nitrogen, and combined carbon. Such solution strengthening enhances the high temperature precipitation-strengthening benefits of fine dispersions of NbC. Such solid solution effects also enhance the stability of the austenite matrix from resistance to excess sigma phase or chrome carbide formation at higher service temperatures. The presence of sulfides is substantially eliminated.
Mazias, Philip J. (Oak Ridge, TN); McGreevy, Tim (Morton, IL); Pollard,Michael James (East Peoria, IL); Siebenaler, Chad W. (Peoria, IL); Swindeman, Robert W. (Oak Ridge, TN)
Effect of homogenization heat treatment on the microstructure and heat-affected zone microfissuring in welded cast alloy 718
The effect of homogenization temperature on microfissuring in the heat-affected zones of electron-beam welded cast INCONEL 718 has been studied. The material was homogenized at various temperatures in the range of 1,037 C and 1,163 C and air-cooled. The homogenized material was then electron-beam welded by the bead-on-plate welding technique. The microstructures and microfissuring in the heat-affected zone (HAZ) were evaluated by analytical scanning electron microscopy (SEM). The grain boundary segregation of various elements was evaluated by secondary ion mass spectroscopy (SIMS). It was observed that the total crack length (TCL) of microfissures first decreases with homogenization temperature and then increases, with a minimum occurring in the specimen heat treated at 1,163 C. This trend coincides with the variation in segregation of B at grain boundaries with homogenization temperature and has been explained by equilibrium and nonequilibrium segregation of B to grain boundaries during the homogenization heat treatment. No other element was observed to segregate at the grain boundaries. The variation in volume fraction of phases like {delta}-Ni{sub 3}Nb, MC carbide, and Laves phases does not follow the same trend as that observed for TCL and B segregation at the grain boundaries. Therefore, microfissuring in HAZ of welded cast INCONEL 718 is attributed to the segregation of B at the grain boundaries.
Xiao Huang; Richards, N.L. [Bristol Aerospace Ltd., Winnipeg, Manitoba (Canada); Chaturvedi, M.C. [Univ. of Manitoba, Winnipeg, Manitoba (Canada). Dept. of Mechanical Engineering
The effect of grain boundary segregation of boron in cast alloy 718 on HAZ microfissuring -- a SIMS analysis
Secondary ion mass spectroscopy (SIMS) has been used to examine grain boundary segregation in cast alloy 718. The relationship between the boron segregation and the microfissuring tendency in heat affected zones (HAZ) around electron beam welds is discussed in this study. It is concluded that two types of segregation, namely equilibrium and non-equilibrium segregation, occurred during the homogenization heat treatment of the base material. Water quenching after the homogenization treatment inhibited non-equilibrium segregation of boron and other trace elements owing to insufficient time for diffusion of solute-vacancy complexes to occur. Intermediate cooling rates such as air cooling enhanced both non-equilibrium and equilibrium segregation, since equilibrium segregation occurred during holding at the heat treatment temperature. The value of net segregation produced by a combination of equilibrium segregation and non-equilibrium segregation varied with temperature in a U-shape. The nature of the grain boundary in the cast alloy was examined by using an electron backscattered diffraction (EBSD) technique and it was found that 93% of the grain boundaries were of the random type ({Sigma} > 49). The weldability of this alloy was found to be closely related to the grain boundary segregation of boron, i.e., the variation of HAZ total crack length (TCL) with pre-welding heat treatment temperatures has a trend similar to that of boron segregation with temperature after air cooling. Mechanisms for the effect of boron on HAZ microfissuring have been proposed.
Huang, X.; Chaturvedi, M.C. [Univ. of Manitoba, Winnipeg, Manitoba (Canada). Dept. of Mechanical and Industrial Engineering; Richards, N.L. [Bristol Aerospace Ltd., Winnipeg, Manitoba (Canada); Jackman, J. [CANMET, Ottawa, Ontario (Canada)
Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Annual subcontract report, 1 January 1996--31 December 1996
This report describes Solarex`s accomplishments during this phase of the Photovoltaic Manufacturing Technology (PVMaT) program. During this reporting period, Solarex researchers converted 79% of production casting stations to increase ingot size and operated them at equivalent yields and cell efficiencies; doubled the casting capacity at 20% the cost of buying new equipment to achieve the same capacity increase; operated the wire saws in a production mode with higher yields and lower costs than achieved on the ID saws; purchased additional wire saws; developed and qualified a new wire-guide coating material that doubles the wire-guide lifetime and produces significantly less scatter in wafer thickness; ran an Al paste back-surface-field process on 25% of all cells in manufacturing; completed environmental qualification of modules using cells produced by an all-print metallization process; qualified a vendor-supplied Tedlar/ethylene vinyl acetate (EVA) laminate to replace the combination of separate sheets of EVA and Tedlar backsheet; substituted RTV adhesive for the 3M Very High Bond tape after several field problems with the tape; demonstrated the operation of a prototype unit to trim/lead attach/test modules; demonstrated the use of light soldering for solar cells; demonstrated the operation of a wafer pull-down system for cassetting wet wafers; and presented three PVMaT-related papers at the 25th IEEE Photovoltaic Specialists Conference.
A recent review by the U.S. Advanced Ceramics Association, the Aluminum Association, and the U.S. Department of Energy's Office of Industrial Technologies (DOE/OIT) described the status of advanced ceramics for aluminum processing, including monolithics, composites, and coatings. The report observed that monolithic ceramics (particularly oxides) have attractive properties such as resistance to heat, corrosion, thermal shock, abrasion, and erosion [1]. However, even after the developments of the past 25 years, there are two key barriers to commercialization: reliability and cost-effectiveness. Industry research is therefore focused on eliminating these barriers. Ceramic coatings have likewise undergone significant development and a variety of processes have been demonstrated for applying coatings to substrates. Some processes, such as thermal barrier coatings for gas turbine engines, exhibit sufficient reliability and service life for routine commercial use. Worldwide, aluminum melting and molten metal handling consumes about 506,000 tons of refractory materials annually. Refractory compositions for handling molten aluminum are generally based on dense fused cast silica or mullite. The microstructural texture is extremely important because an interlocking mass of coarser grains must be bonded together by smaller grains in order to achieve adequate strength. At the same time, well-distributed microscopic pores and cracks are needed to deflect cracks and prevent spalling and thermal shock damage [2]. The focus of this project was to develop and validate new classes of cost-effective, low-permeability ceramic and refractory components for handling molten aluminum in both smelting and casting environments. The primary goal was to develop improved coatings and functionally graded materials that will possess superior combinations of properties, including resistance to thermal shock, erosion, corrosion, and wetting. When these materials are successfully deployed in aluminum smelting and casting operations, their superior performance and durability will give end users marked improvements in uptime, defect reduction, scrap/rework costs, and overall energy savings resulting from higher productivity and yield. The implementation of results of this program will result in energy savings of 30 trillion Btu/year by 2020. For this Industrial Materials for the Future (IMF) project, riser tube used in the low-pressure die (LPD) casting of aluminum was selected as the refractory component for improvement. In this LPD process, a pressurized system is used to transport aluminum metal through refractory tubes (riser tubes) into wheel molds. It is important for the tubes to remain airtight because otherwise, the pressurized system will fail. Generally, defects such as porosity in the tube or cracks generated by reaction of the tube material with molten aluminum lead to tube failure, making the tube incapable of maintaining the pressure difference required for normal casting operation. Therefore, the primary objective of the project was to develop a riser tube that is not only resistant to thermal shock, erosion, corrosion, and wetting, but is also less permeable, so as to achieve longer service life. Currently, the dense-fused silica (DFS) riser tube supplied by Pyrotek lasts for only 7 days before undergoing failure. The following approach was employed to achieve the goal: (1) Develop materials and methods for sealing surface porosity in thermal-shock-resistant ceramic refractories; (2) Develop new ceramic coatings for extreme service in molten aluminum operations, with particular emphasis on coatings based on highly stable oxide phases; (3) Develop new monolithic refractories designed for lower-permeability applications using controlled porosity gradients and particle size distributions; (4) Optimize refractory formulations to minimize wetting by molten aluminum, and characterize erosion, corrosion, and spallation rates under realistic service conditions; and (5) Scale up the processing methods to full-sized components and perform field testi
Kadolkar, Puja [ORNL; Ott, Ronald D [ORNL
Go-ing for the prediction of protein folding mechanisms
of Chemistry, Faculty of Science, Kobe University, Kobe, 657-8501, Japan Protein folding has been a long-lived could be relatively simple. These three ingredients are linked together with an almost one-line free work (8, 9). The surprise of the three papers is that apparently one can have both simplicity and fair
Takada, Shoji
The physical function-ing of a city sometimes
insurance. It is recommended that parents carefully review their homeowners, auto and health insurance. Parents should check their homeowners policy to see whether it will cover a student's possessions while
Development of Stronger and More Reliable Cast Austenitic Stainless Steels (H-Series) Based on Scientific Design Methodology
The goal of this program was to increase the high-temperature strength of the H-Series of cast austenitic stainless steels by 50% and upper use temperature by 86 to 140 F (30 to 60 C). Meeting this goal is expected to result in energy savings of 38 trillion Btu/year by 2020 and energy cost savings of $185 million/year. The higher strength H-Series of cast stainless steels (HK and HP type) have applications for the production of ethylene in the chemical industry, for radiant burner tubes and transfer rolls for secondary processing of steel in the steel industry, and for many applications in the heat-treating industry. The project was led by Duraloy Technologies, Inc. with research participation by the Oak Ridge National Laboratory (ORNL) and industrial participation by a diverse group of companies. Energy Industries of Ohio (EIO) was also a partner in this project. Each team partner had well-defined roles. Duraloy Technologies led the team by identifying the base alloys that were to be improved from this research. Duraloy Technologies also provided an extensive creep data base on current alloys, provided creep-tested specimens of certain commercial alloys, and carried out centrifugal casting and component fabrication of newly designed alloys. Nucor Steel was the first partner company that installed the radiant burner tube assembly in their heat-treating furnace. Other steel companies participated in project review meetings and are currently working with Duraloy Technologies to obtain components of the new alloys. EIO is promoting the enhanced performance of the newly designed alloys to Ohio-based companies. The Timken Company is one of the Ohio companies being promoted by EIO. The project management and coordination plan is shown in Fig. 1.1. A related project at University of Texas-Arlington (UT-A) is described in Development of Semi-Stochastic Algorithm for Optimizing Alloy Composition of High-Temperature Austenitic Stainless Steels (H-Series) for Desired Mechanical and Corrosion Properties (ORNL/TM-2005/81/R1). The final report on another related project at the University of Tennessee by George Pharr, Easo George, and Michael Santella has been published as Development of Combinatorial Methods for Alloy Design and Optimization (ORNL/TM-2005-133). The goal of the project was to increase the high-temperature strength by 50% and upper use temperature by 86 to 140 F (30 to 60 C) of H-Series of cast austenitic stainless steels. Meeting such a goal is expected to result in energy savings of 38 trillion Btu/year by 2020 and energy cost savings of $185 million/year. The goal of the project was achieved by using the alloy design methods developed at ORNL, based on precise microcharacterization and identification of critical microstructure/properties relationships and combining them with the modern computational science-based tools that calculate phases, phase fractions, and phase compositions based on alloy compositions. The combined approach of microcharacterization of phases and computational phase prediction would permit rapid improvement of the current alloy composition of an alloy and provide the long-term benefit of customizing alloys within grades for specific applications. The project was appropriate for the domestic industry because the current H-Series alloys have reached their limits both in high-temperature-strength properties and in upper use temperature. The desire of Duraloy's industrial customers to improve process efficiency, while reducing cost, requires that the current alloys be taken to the next level of strength and that the upper use temperature limit be increased. This project addressed a specific topic from the subject call: to develop materials for manufacturing processes that will increase high-temperature strength, fatigue resistance, corrosion, and wear resistance. The outcome of the project would benefit manufacturing processes in the chemical, steel, and heat-treating industries.
Muralidharan, G.; Sikka, V.K.; Pankiw, R.I.
Reactions with water of as-cast uranium-carbon alloys containing 2to 10 wt% carbon (UC/sub 0.4/ to UC/sub 2.2/) were investigated by using gas- chromatography for analysis of the gaseous products. Uranium metal-uranium monocarbide alloys yielded 2 moles of free hydrogen per mole of free metal, in addition to methane, small quantities of higher molecular weight gaseous hydrocarbons, and a solid, hydrous, tetravalent uranium oxide. The gaseous producte contained all the carbon originally present in the alloy. Uranium dicarbide (UC/sub 1.86/; this combined-C/U atom ratio was the maximum which could be obtained) yielded a mixture of 38 hydrocarbons (methane, 15 vol%; ethane, 28%: C/sub 3/- to C/sub 8/-alkanes, 7%; alkenes, 8%; alkynes, 0.6%; and widentified unsaturates, 1%), free hydrogen (40 vol%), a water-insoluble wax, and a solid, hydrous, tetravalent uranium oxide. Forty% of the combined carbon was found in the gas and 25% in the wax. The gaseous products from the hydrolysis of both UC and UC/sub 1.86/ were not affected by changes in the reaction temperature between 25 and 99 deg . The composition of the gases evolved at 80 deg from as-cast alioys with compositions between UC and UC/sub 1.86/ varied linearly with the combined-C/U atom ratio of the alloy; however, the amounts of methane produced were lower than expected from the UC concentrations in the alloys. (auth)
Bradley, M.J.; Ferris, L.M.
Cast House Productivity and Strip Casting
Feb 17, 2010... in a remelt context, production and maintenance planning, training and culture. ... microscopy (SEM) and transmission electron microscopy (TEM). ... Canada recently completed a major plant expansion that includes a new�...
Multifunctional virus scaffolds fore energy applications : nanomaterials synthesis and two dimensional assembly
Biological systems inherently posses the ability to synthesize and assemble nanomaterials with remarkable precision, as evident in biomineralization. These unique abilities of nature continue to inspire us to develop new ...
Nam, Ki Tae
Molecular Chemistry to the Fore: New Insights into the Fascinating World of Photoactive Colloidal Semiconductor Nanocrystals
Colloidal semiconductor nanocrystals possess unique properties that are unmatched by other chromophores such as organic dyes or transition-metal complexes. These versatile building blocks have generated much scientific interest and found applications in bioimaging, tracking, lighting, lasing, photovoltaics, photocatalysis, thermoelectrics, and spintronics. Despite these advances, important challenges remain, notably how to produce semiconductor nanostructures with predetermined architecture, how to produce metastable semiconductor nanostructures that are hard to isolate by conventional syntheses, and how to control the degree of surface loading or valence per nanocrystal. Molecular chemists are very familiar with these issues and can use their expertise to help solve these challenges. In this Perspective, we present our group�s recent work on bottom-up molecular control of nanoscale composition and morphology, low-temperature photochemical routes to semiconductor heterostructures and metastable phases, solar-to-chemical energy conversion with semiconductor-based photocatalysts, and controlled surface modification of colloidal semiconductors that bypasses ligand exchange.
Vela-Becerra, Javier [Ames Laboratory
Forewarned and Fore-ARM-ed Against Climate Changes and Challenges
layer, which in a sense is where the ocean meets the sky, where heat and evaporating water rising off the ocean run into the air flowing freely through the atmosphere. It's a...
60SHELLSOLARINDUSTRIESWaiverofDomesticandfore.pdf WA05060SHELLSOLARINDUSTRIESWaiverofDomesticandfore.pdf WA05060SHELLSOLARINDUSTRIESWaiverofDomesticandf...
CONF-901007--48 Pi! ' " DR91 006 500
/FPY. Therefore, the total amount The H is generated by the D-D reaction in the of" tritium remained inside to separate the H from D and T while keep- ,is the tritium inventory. There are three ing the D/T ratio at I. fore, we use a Pd diffuser for separation of This can be accomplished with a divertor hydrogen isotopes
Harilal, S. S.
Materials Reliability Program: Technical Basis for ASME Section XI Code Case on Flaw Tolerance of Cast Austenitic Stainless Steel (CASS) Piping (MRP-362)
Thermal aging of cast austenitic stainless steel (CASS) piping is a concern for long-term operation of nuclear power plants. The effects of aging in susceptible (i.e., high delta ferrite) CASS piping and components must be managed through the license renewal period. In the United States, utilities must follow the guidance for managing age-related degradation identified in the Generic Aging Lessons Learned (GALL) report, which may include analyses or inspections to demonstrate that the piping systems ...
Heat exchanger-ingot casting/slicing process. Silicon sheet growth development for the Large Area Silicon Sheet Task of the Low Cost Silicon Solar Array Project. Second quarterly progress report, January 1, 1976--March 31, 1976
The object of this program is to demonstrate that large single-crystal ingots can be economically cast by the Heat Exchanger Method (HEM) and economically sliced into thin sheets with a multi-wafer slicer. An experimental program is described which is designed to demonstrate the potential and isolate the limiting parameters for crystal casting and slicing with the Heat Exchanger Method (HEM) and the multi-wafer slicer. (WDM)
Schmid, F.
A high precision instrument to measure angular and binocular deviation introduced by aircraft windscreens by using a shadow casting technique
Objects viewed through transparent sheets with residual non-parallelism and irregularity appear shifted and distorted. This distortion is measured in terms of angular and binocular deviation of an object viewed through the transparent sheet. The angular and binocular deviations introduced are particularly important in the context of aircraft windscreens and canopies as they can interfere with decision making of pilots especially while landing, leading to accidents. In this work, we have developed an instrument to measure both the angular and binocular deviations introduced by transparent sheets. This instrument is especially useful in the qualification of aircraft windscreens and canopies. It measures the deviation in the geometrical shadow cast by a periodic dot pattern trans-illuminated by the distorted light beam from the transparent test specimen compared to the reference pattern. Accurate quantification of the shift in the pattern is obtained by cross-correlating the reference shadow pattern with the specimen shadow pattern and measuring the location of the correlation peak. The developed instrument is handy to use and computes both angular and binocular deviation with an accuracy of less than {+-}0.1 mrad ( Almost-Equal-To 0.036 mrad) and has an excellent repeatability with an error of less than 2%.
Shivananju, B. N.; Yamdagni, S. [Department of Instrumentation and Applied Physics, Indian Institute of Science, Bangalore 560012 (India); Vasu, R. M. [Department of Instrumentation and Applied Physics, Indian Institute of Science, Bangalore 560012 (India); Applied Photonics Initiative, Indian Institute of Science, Bangalore 560012 (India); Asokan, S. [Department of Instrumentation and Applied Physics, Indian Institute of Science, Bangalore 560012 (India); Applied Photonics Initiative, Indian Institute of Science, Bangalore 560012 (India); Robert Bosch Centre for Cyber Physical Systems, Indian Institute of Science, Bangalore 560012 (India)
Full surface local heat transfer coefficient measurements in a model of an integrally cast impingement cooling geometry
Cast impingement cooling geometries offer the gas turbine designer higher structural integrity and improved convective cooling when compared to traditional impingement cooling systems, which rely on plate inserts. In this paper, it is shown that the surface that forms the jets contributes significantly to the total cooling. Local heat transfer coefficient distributions have been measured in a model of an engine wall cooling geometry using the transient heat transfer technique. The method employs temperature-sensitive liquid crystals to measure the surface temperature of large-scale perspex models during transient experiments. Full distributions of local Nusselt number on both surfaces of the impingement plate, and on the impingement target plate, are presented at engine representative Reynolds numbers. The relative effects of the impingement plate thermal boundary condition and the coolant supply temperature on the target plate heat transfer have been determined by maintaining an isothermal boundary condition at the impingement plate during the transient tests. The results are discussed in terms of the interpreted flow field.
Gillespie, D.R.H.; Wang, Z.; Ireland, P.T. [Univ. of Oxford (United Kingdom). Dept. of Engineering Science; Kohler, S.T. [Rolls Royce, Bristol (United Kingdom)
Phased Array Ultrasonic Sound Field Mapping through Large-Bore Coarse Grained Cast Austenitic Stainless Steel (CASS) Components
A sound field beam mapping exercise was conducted to assist in understanding the effects of coarse-grained microstructures found in cast austenitic stainless steel (CASS) materials on acoustic longitudinal wave propagation. Ultrasonic laboratory measurements were made on three specimens representing four different grain structures. Phased array (PA) probes were fixed on each specimen surface and excited in the longitudinal mode at specific angles while a point receiver was scanned in a raster pattern over the end of the specimen, generating a transmitted sound field image. Three probes operating at nominal frequencies of 0.5, 0.8, and 1.0 MHz were used. A 6.4 mm (0.25-in.) thick slice was removed from the specimen end and beam mapping was repeated three times, yielding four full sets of beam images. Data were collected both with a constant part path for each configuration (probe, specimen and slice, angle, etc.) and with a variable part path (fixed position on the surface). The base specimens and slices were then polished and etched to reveal measureable grain microstructures that were compared to the sound field interactions and scattering effects seen in the collected data.
Crawford, Susan L.; Cinson, Anthony D.; Prowant, Matthew S.; Coble, Jamie B.; Diaz, Aaron A.; Anderson, Michael T.
Improvements in Low-Frequency, Ultrasonic Phased-Array Evaluation for Thick Section Cast Austenitic Stainless Steel Piping Components
Research is being conducted for the U.S. Nuclear Regulatory Commission (NRC) at the Pacific Northwest National Laboratory (PNNL) to assess the effectiveness and reliability of advanced nondestructive examination (NDE) methods for the inspection of light water reactor (LWR) components. A primary objective of this work is to evaluate various NDE methods to assess their ability to detect, localize, and size cracks in coarse-grained steel components. This particular study focused on the evaluation of custom-designed, low-frequency (500 kHz) phased-array (PA) probes for examining welds in thick-section cast austenitic stainless steel (CASS) piping. In addition, research was conducted to observe ultrasonic sound field propagation effects from known coarse-grained microstructures found in parent CASS material. The study was conducted on a variety of thick-wall, coarse-grained CASS specimens that were previously inspected by an older generation 500-kHz PA-UT probe and acquisition instrument configuration. This comparative study describes the impact of the new PA probe design on flaw detection and sizing in a low signal-to-noise environment. The set of Pressurized Water Reactor Owners Group (PWROG) CASS specimens examined in this study are greater than 50.8-mm (2.0-in.) thick with documented flaws and microstructures. These specimens are on loan to PNNL from the Electric Power Research Institute (EPRI) NDE Center in Charlotte, North Carolina. The flaws contained within these specimens are thermal fatigue cracks (TFC) or mechanical fatigue cracks (MFC) and range from 13% to 42% in through-wall extent. In addition, ultrasonic signal continuity was evaluated on two CASS parent material ring sections by examining the edge-of-pipe response (corner geometry) for regions of signal loss.
Anderson, Michael T.; Crawford, Susan L.; Diaz, Aaron A.; Moran, Traci L.
Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual technical report, 1 January 1996--30 June 1996
Two specific objectives of Solarex`s program are to reduce the manufacturing cost for polycrystalline silicon photovoltaic modules to less than $1.20/watt and to increase the manufacturing capacity by a factor of three. This report highlights accomplishments during the period of January 1 through June 30, 1996. Accomplishments include: began the conversion of production casting stations to increase ingot size; operated the wire saw in a production mode with higher yields and lower costs than achieved on the ID saws; developed and qualified a new wire guide coating material that doubles the wire guide lifetime and produces significantly less scatter in wafer thickness; completed a third pilot run of the cost-effective Al paste back-surface-field (BSF) process, verifying a 5% increase in cell efficiency and demonstrating the ability to process and handle the BSF paste cells; completed environmental qualification of modules using cells produced by an all-print metallization process; optimized the design of the 15.2-cm by 15.2-cm polycrystalline silicon solar cells; demonstrated the application of a high-efficiency process in making 15.2-cm by 15.2-cm solar cells; demonstrated that cell efficiency increases with decreasing wafer thickness for the Al paste BSF cells; qualified a vendor-supplied Tedlar/ethylene vinyl acetate (EVA) laminate to replace the combination of separate sheets of EVA and Tedlar backsheet; demonstrated the operation of a prototype unit to trim/lead attach/test modules; and demonstrated the operation of a wafer pull-down system for cassetting wet wafers.
Heat transfer at the mold-metal interface in permanent mold casting of aluminum alloys project. Annual project status report for the period October 1, 1997 to September 30, 1998
In the first year of this three-year project, substantial progress has been achieved. This project on heat transfer coefficients in metal permanent mold casting is being conducted in three areas. They are the theoretical study at the University of Michigan, the experimental investigations of squeeze casting and semi-solid casting at CMI-Tech Center, and the experimental investigation of low pressure permanent mold casting at Amcast Automotive. U-M did an initial geometry which was defined for ProCAST to solve, and then a geometry half the size was defined and solved using the same boundary conditions. A conceptual mold geometry was examined and is represented as an axisymmetric element.Furthermore, the influences of the localized heat transfer coefficients on the casting process were carefully studied. The HTC Evaluator has been proposed and initially developed by the U-M team. The Reference and the Database Modules of the HTC Evaluator have been developed, and extensively tested. A series of technical barriers have been cited and potential solutions have been surveyed. At the CMI-Tech Center, the Kistler direct cavity pressure measurement system has been purchased and tested. The calibrations has been evaluated. The probe is capable of sensing a light finger pressure. The experimental mold has been designed and modified. The experimental mold has been designed and modified. The first experiment is scheduled for October 14, 1998. The geometry of the experimental hockey-puck casting has been given to the U-M team for numerical analysis.
Energy Saving Melting and Revert Reduction Technology (E-SMARRT): Development of Surface Engineered Coating Systems for Aluminum Pressure Die Casting Dies: Towards a 'Smart' Die Coating
The main objective of this research program was to design and develop an optimal coating system that extends die life by minimizing premature die failure. In high-pressure aluminum die-casting, the die, core pins and inserts must withstand severe processing conditions. Many of the dies and tools in the industry are being coated to improve wear-resistance and decrease down-time for maintenance. However, thermal fatigue in metal itself can still be a major problem, especially since it often leads to catastrophic failure (i.e. die breakage) as opposed to a wear-based failure (parts begin to go out of tolerance). Tooling costs remain the largest portion of production costs for many of these parts, so the ability prevent catastrophic failures would be transformative for the manufacturing industry.The technology offers energy savings through reduced energy use in the die casting process from several factors, including increased life of the tools and dies, reuse of the dies and die components, reduction/elimination of lubricants, and reduced machine down time, and reduction of Al solder sticking on the die. The use of the optimized die coating system will also reduce environmental wastes and scrap parts. Current (2012) annual energy saving estimates, based on initial dissemination to the casting industry in 2010 and market penetration of 80% by 2020, is 3.1 trillion BTU's/year. The average annual estimate of CO2 reduction per year through 2020 is 0.63 Million Metric Tons of Carbon Equivalent (MM TCE).
Dr. John J. Moore; Dr. Jianliang Lin,
M.D. Hurd, L.J. Laviolette and M.E. Lewellyn. Mitigation of ... The Determination of the Exposure to Electromagnetic Fields in Aluminum Electrolysis [pp. 253-259
Casting & Solidification 8
Jun 7, 2012 ... 9:15 AM SEM Study on Short Time Oxide Films in Molten Pure Aluminium: Behzad Nayebi1; Mehdi Divandari1; 1Iran University of Science and�...
Aluminum Cast Shop IV
Mar 6, 2013 ... The energy released from one kilogram of molten aluminium reacted with oxygen is equivalent to detonating 3 kilograms of trinitrotoluene�...
Upgradation of Alumina Refinery at Hindalco Renukoot (India) R.P. Shah and .... The Influence of Crude Oil Desalting on Calcined Coke Quality (abstract only)
Steelmaking and Casting III
Scotland's iron production resumed ?1780, based on coal/ore around Glasgow. By ?1850, wrought iron (WI) plates spawned shipbuilding (open-hearth steel�...
Melting and Casting Practice
...crucible and open flame furnaces as well as electric induction furnaces. Both core type and coreless induction melters are widely used. Copper alloys are poured into many types of molds such as
This patent covers a method and apparatus for collecting the molten metal produced by high temperature metal salt reduction. It consists essentially of subjecting the reaction vessel to centrifugal force in order to force the liberatcd molten metal into a coherent molten mass, and allowing it to solidify there. The apparatus is particularly suitable for use with small quantities of rare metals.
Magel, T.T.
cast shop technology ii
Energy Efficiency Considerations on Monopolar Versus Bipolar Fused Salt .... Use of a Technical Audit to Improve the Safe Handling of Molten Materials [pp.
Investment Casting of Superalloys
a large absorption of heat by the nucleant resulting in an increase in the cooling rate during solidification. Explanations for this heat absorption indicate either the
Leonard S. Aubrey, DawidD. Smith � andLuiz C.B. Martins � Measurements of the ... Jim Pear son and Paul Cooper � Recent Developments in Aluminum Scrap�...
Modeling Investment Castings
Once the finite-element meshes of the metal, mold, mold wrap, and furnace are created, they are assembled into a final model as shown in Figure 6. It is then�...
Steelmaking and Casting IV
Oct 31, 2013 ... Session Chair: Emmanuel De Moor, Colorado School of Mines ... investigated at 1300�C and 1400�C using iron crucibles and argon gas. ... oxide inclusions rapid profiling and blast furnacethe analysis of the requirements,�...
Preparation of anisotropic Nd(Fe,Mo){sub 12}N{sub 1.0} magnetic materials by strip casting technique and direct nitrogenation for the strips
The Nd(Fe,Mo){sub 12}-type alloys are prepared by strip casting technique, and direct nitrogenation of the strips without precrushing is executed in this paper. It is found that 6 h annealing treatment at 1050 deg. C for the strips is enough to obtain the single-phase Nd(Fe,Mo){sub 12} compounds. The strips can be directly nitrogenated at 620 deg. C to obtain interstitial Nd(Fe,Mo){sub 12}N{sub 1.0} materials, and a spontaneous pulverization phenomenon in the strips induced by nitrogenation is found. The results indicate that the nitrogenation process of the strips can be used to prepare Nd(Fe,Mo){sub 12}N{sub 1.0} interstitial nitrides and pulverize the casted strips into fine particles simultaneously. Base on this, we propose a new technical route of preparing Nd(Fe,Mo){sub 12}N{sub X} magnetic powders without precrushing and obtain anisotropic NdFe{sub 10.5}Mo{sub 1.5}N{sub 1.0} powders with a remanence of B{sub r} = 1.08 T, a coercivity of {sub i}H{sub c} = 400 kA/m, and a maximum energy product of (BH){sub max} = 144 kJ/m{sup 3}.
Han Jingzhi; Liu Shunquan; Xing Meiying; Lin Zhong; Kong Xiangpeng; Wang Changsheng; Du Honglin; Yang Yingchang [School of Physics, Peking University, Beijing 100871 (China); Yang Jinbo [School of Physics, Peking University, Beijing 100871 (China); State Key Laboratory for Artificial Microstructure and Mesoscopic Physics, School of Physics, Peking University, Beijing 100871 (China)
Heat exchanger-ingot casting/slicing process. Silicon Sheet Growth Development for the Large Area Silicon Sheet Task of the Low Cost Silicon Solar Array Project. Eighth quarterly progress report, July 1, 1977--September 30, 1977
Graded crucibles have been developed which are dense enough to avoid penetration of the molten silicon and weak enough to fracture during the cool-down cycle. These crucibles have been used to cast crack-free silicon ingots up to 3.3 kg. Significant progress has been made in the crystallinity of the samples cast. Solar cells made from one of the ingots have yielded over 9% conversion efficiency. The source of silicon carbide in the cast silicon has been identified, both theoretically and experimentally, to be associated with the use of graphite retainers in contact with the crucible. Both 45 ..mu..m and 30 ..mu..m diamonds can be used for efficient slicing of silicon. Wafers sliced with 45 ..mu..m diamond plated wire show a surface roughness of +-0.5 ..mu..m and extent of damage of 3 ..mu..m. In an effort to avoid diamond pullout from impregnated wire it was found that a layer of 0.3 mil thick plating is sufficient to encapsulate the diamonds. A projected cost analysis has shown that the add-on cost of casting and slicing of silicon is $11.57 per square meter.
Schmid, F.; Khattak, C.P.
Heat exchanger: ingot casting/slicing process. Silicon sheet growth development for the large area silicon sheet task of the low cost silicon solar array project. First quarterly report, November 20, 1975--December 31, 1975
Designs for changes to the existing crystal casting furnace and multi-wafer slicer were completed prior to the contract. Equipment supplies necessary for the modifications and silicon material were ordered during the first one and one-quarter month period covered. Assembly preparation and check-out of all systems are on schedule. (auth)
Search for 14.4-KeV Solar Axions Emitted in the M1-Transition of Fe-57 Nuclei with CAST
We have searched for 14.4 keV solar axions or more general axion-like particles (ALPs), that may be emitted in the M1 nuclear transition of 57Fe, by using the axion-to-photon conversion in the CERN Axion Solar Telescope (CAST) with evacuated magnet bores (Phase I). From the absence of excess of the monoenergetic X-rays when the magnet was pointing to the Sun, we set model-independent constraints on the coupling constants of pseudoscalar particles that couple to two photons and to a nucleon g{sub ay}|-1.19g{sub aN}{sup 0}+g{sub aN}{sup 3}| < 1.36 x 10{sup -16} GeV{sup -1} for ma < 0.03 eV at the 95% confidence level.
Andriamonje, S.; Aune, S.; /DAPNIA, Saclay; Autiero, D.; /CERN /Lyon, IPN; Barth, K.; /CERN; Belov, A.; /Moscow, INR; Beltran, B.; /Zaragoza U. /Queen's U., Kingston; Brauninger, H.; /Garching, Max Planck Inst., MPE; Carmona, J.M.; Cebrian, S.; /Zaragoza U.; Collar, J.I.; /Chicago U., EFI /Chicago U., KICP; Dafni, T.; /DAPNIA, Saclay /Darmstadt, Tech. Hochsch. /Zaragoza U.; Davenport, M.; /CERN; Di Lella, L.; /CERN /Pisa, Scuola Normale Superiore; Eleftheriadis, C.; /Aristotle U., Thessaloniki; Englhauser, J.; /Garching, Max Planck Inst., MPE; Fanourakis, G.; /Democritos Nucl. Res. Ctr.; Ferrer-Ribas, E.; /DAPNIA, Saclay; Fischer, H.; Franz, J.; /Freiburg U.; Friedrich, P.; /Garching, Max Planck Inst., MPE; Geralis, T.; /Democritos Nucl. Res. Ctr. /DAPNIA, Saclay /Moscow, INR /Zaragoza U. /British Columbia U. /Freiburg U. /Darmstadt, Tech. Hochsch. /DAPNIA, Saclay /Zaragoza U. /Frankfurt U. /Boskovic Inst., Zagreb /Freiburg U. /Munich, Max Planck Inst. /Boskovic Inst., Zagreb /Democritos Nucl. Res. Ctr. /Darmstadt, Tech. Hochsch. /Garching, Max Planck Inst., MPE /Boskovic Inst., Zagreb /CERN /Aristotle U., Thessaloniki /Boskovic Inst., Zagreb /Munich, Max Planck Inst. /Zaragoza U. /Chicago U., EFI /Chicago U., KICP /Stanford U., Phys. Dept. /SLAC /Zaragoza U. /CERN /DAPNIA, Saclay /CERN /Munich, Max Planck Inst. /Darmstadt, Tech. Hochsch. /Zaragoza U. /Aristotle U., Thessaloniki /Patras U. /Brookhaven /CERN /Munich, Max Planck Inst. /CERN /Chicago U., EFI /Chicago U., KICP /Zaragoza U. /Freiburg U. /CERN /CERN /Patras U.
Numerical Weather Predictions (NWP) can be regarded as the backbone for energy meteorol-
Abstract Numerical Weather Predictions (NWP) can be regarded as the backbone for energy meteorol- ogists when predicting highly fluctuating wind and solar power. While the meteorological fore- cast) is simulated with weather analysis and NWP forecasts. The distributed generation of wind power is favorable
Heinemann, Detlev
ELI Student Voices 1 ELI STUDENT VOICESVolume 5, Issue 3 Fall 2001
to a soldier in a combat venue. "When I was deployed to Saudi Arabia during the first Gulf War, I received on the link for "Boston College." --SS the weather up there Radio and TV weather fore- casts tell us about in the future might they also warn of un- usual solar activity? One Boston College scientist thinks it could
Choate, Paul M.
Addressing Our Global Water Future Center for Strategic and International Studies (CSIS)
Fuerschbach, Phillip
Electronic copy available at: http://ssrn.com/abstract=2014739 Published as: Amir Nosrat and Joshua M. Pearce, "Dispatch Strategy and Model for Hybrid Photovoltaic and Combined Heating,
Paris-Sud XI, Université de
arXiv:astro-ph/0503363v116Mar2005 Self-Calibration of Cluster Dark Energy Studies: Observable-Mass Distribution
of the observable-mass distribution that will protect against misinterpretation of the dark energy constraints. I, uncertainties in the distribution directly translate into uncertainties in the dark energy inferences that must-mass distribution on high redshift cluster counts. Previous work on fore- casting prospects for dark energy
Hu, Wayne
Vertical migration of the toxic dinoflagellate Karenia brevis and the impact on ocean optical properties
, Inc.) coupled to a fiber-optic spectrometer (S2000, Ocean Optics, Inc.) and a fiber-optic xenon flash. Moline, and C. S. Roesler (1999), Optical monitoring and fore- casting systems for harmful algal bloomsVertical migration of the toxic dinoflagellate Karenia brevis and the impact on ocean optical
Mathematical models of natural gas consumption
Mathematical models of natural gas consumption Kristian Sabo, Rudolf Scitovski, Ivan of natural gas consumption Kristian Sabo, Rudolf Scitovski, Ivan Vazler , Marijana Zeki-Susac ksabo of natural gas consumption hourly fore- cast on the basis of hourly movement of temperature and natural gas
Scitovski, Rudolf
Post-Construction Evaluation of Forecast Accuracy Pavithra Parthasarathi1
Post-Construction Evaluation of Forecast Accuracy Pavithra Parthasarathi1 David Levinson 2 February the accuracy of demand forecasts using a sample of recently-completed projects in Minnesota and identifies the factors influencing the inaccuracy in forecasts. The fore- cast traffic data for this study is drawn from
Levinson, David M.
Short-Term Load Forecasting This paper discusses the state of the art in short-term load fore-
aspects for the development and usage of STLF models and packages. The annotated bibliography offersGas & Electric Co., San Francisco, CA F. D. Galiana is with the Department of Electrical Engineering, IEEE Log
Gross, George
Improvements in 500-kHz Ultrasonic Phased-Array Probe Designs for Evaluation of Thick Section Cast Austenitic Stainless Steel Piping Welds
PNNL has been studying and performing confirmatory research on the inspection of piping welds in coarse-grained steels for over 30 years. More recent efforts have been the application of low frequency phased array technology to this difficult to inspect material. The evolution of 500 kHz PA probes and the associated electronics and scanning protocol are documented in this report. The basis for the probe comparisons are responses from one mechanical fatigue crack and two thermal fatigue cracks in large-bore cast mockup specimens on loan from the Electric Power Research Institution. One of the most significant improvements was seen in the use of piezo-composite elements in the later two probes instead of the piezo-ceramic material used in the prototype array. This allowed a reduction in system gain of 30 dB and greatly reduced electronic noise. The latest probe had as much as a 5 dB increase in signal to noise, adding to its flaw discrimination capability. The system electronics for the latest probe were fully optimized for a 500 kHz center frequency, however significant improvements were not observed in the center frequency of the flaw responses. With improved scanner capabilities, smaller step sizes were used, allowing both line and raster data improvements to be made with the latest probe. The small step sizes produce high resolution images that improve flaw discrimination and, along with the increased signal-to-noise ratio inherent in the latest probe design, enhanced detection of the upper regions of the flaw make depth sizing more plausible. Finally, the physical sizes of the probes were progressively decreased allowing better access to the area of interest on specimens with weld crowns, and the latest probe was designed with non-integral wedges providing flexibility in focusing on different specimen geometries.
Crawford, Susan L.; Cinson, Anthony D.; Moran, Traci L.; Anderson, Michael T.; Diaz, Aaron A.
CAST SHOP TECHNOLOGY: VIII: D.C. Casting
Three-dimensional simulations of the coupled fluid flow and heat transfer problem ... flat rolling sheet ingots, such molds produce W-type ingot cross section.
CAST SHOP TECHNOLOGY: VI: Solidification of Cast Alloys
Finite element modeling has become widely to used simulate the filling, .... i.e., rough/shrinkage pores and smooth/hydrogen pores, can be distinguished by ... in the form of hollow microspheres, a ceramic by-product from coal power stations.
Heat exchanger-ingot casting/slicing process. Silicon sheet growth development for the Large Area Silicon Sheet Task of the Low Cost Silicon Solar Array Project. Final report, Phase I, November 20, 1975--November 20, 1977
The proof of concept for silicon casting by the Heat Exchanger Method has been established. One of the major hurdles of ingot cracking has been eliminated with the development of graded crucibles. Such crucibles are compatible with the casting process in that the integrity of the container is maintained at high temperature; however, during the cool-down cycle the crucible fails, thereby leaving a crack-free boule. The controlled growth, heat-flow and cool-down has yielded silicon with a high degree of single crystallinity. Even when the seed melted out, very large grains formed. Solar cell samples made from cast material have yielded conversion efficiency of over 9% (AMI). Representative characterizations of silicon grown has demonstrated a dislocation density of less than 100/cm/sup 2/ and a minority carrier diffusion length of 31 ..mu..m. Excellent surface quality, i.e., surface smoothness and 3 to 5 ..mu..m surface damage, was achieved by multiple wire slicing with fixed diamond abrasive. To achieve this, the silicon workpiece was non-synchronously rocked to produce a radial cut profile and minimize wire contact length. Wire wander was reduced an order of magnitude over the original results by supporting and guiding the wires with grooved rollers. Commercially available impregnated wires that were used failed due to diamond pull-out. Plating after impregnation or electroplating diamonds directly on the core minimized diamond pull-out and corresponding loss in cutting effectiveness. Tungsten wire was the best core material tested because of its high strength, high Young's modulus, and resistance to hydrogen embrittlement. A lighter and longer blade carriage can be used for slicing with wire. This will allow the blade carriage to be reciprocated more rapidly to increase the surface speed. A projected add-on cost calculation shows that these methods will yield silicon for solar cell applications within ERDA/JPL cost goals.
Schmid, F; Khattak, C P
Heat exchanger-ingot casting/slicing process. Silicon sheet growth development for the large area silicon sheet task of the low cost Silicon Solar Array Project. Third quarterly progress report, April 1, 1976--June 18, 1976
The object of this program is to demonstrate that large single-crystal ingots, 6-inch diameter by 4 inches tall, can be economically cast by the Heat Exchanger Method (HEM) and economically sliced into thin sheets, 0.008-inches thick, with a multi-wafer slicer. The thrust of the experimental work during this quarter was to establish the proper seed meltback and to nucleate single-crystal growth off the seed. Slicing tests were begun on the multi-blade wafering machine, using a newly fabricated sensitive feed mechanism and associated components. (WDM)
Schmid, F.; Reynolds, B.
Technical Letter Report Assessment of Ultrasonic Phased Array Inspection Method for Welds in Cast Austenitic Stainless Steel Pressurizer Surge Line Piping JCN N6398, Task 1B
Research is being conducted for the U.S. Nuclear Regulatory Commission (NRC) at the Pacific Northwest National Laboratory (PNNL) to assess the effectiveness and reliability of advanced nondestructive examination (NDE) methods for the inspection of light water reactor components. The scope of this research encompasses primary system pressure boundary materials including cast austenitic stainless steels (CASS); dissimilar metal welds; piping with corrosion-resistant cladding; weld overlays, inlays and onlays; and far-side examinations of austenitic piping welds. A primary objective of this work is to evaluate various NDE methods to assess their ability to detect, localize, and size cracks in coarse-grained steel components. In this effort, PNNL supports cooperation with Commissariat � l�Energie Atomique (CEA) to assess reliable inspection of CASS materials. The NRC Project Manager has established a cooperative effort with the Institut de Radioprotection et de Surete Nucleaire (IRSN). CEA, under funding from IRSN, are supporting collaborative efforts with the NRC and PNNL. Regarding its work on the NDE of materials, CEA is providing its modeling software (CIVA) in exchange for PNNL offering expertise and data related to phased-array detection and sizing, acoustic attenuation, and back scattering on CASS materials. This collaboration benefits the NRC because CEA performs research and development on CASS for �lectricit� de France (EdF). This technical letter report provides a summary of a technical evaluation aimed at assessing the capabilities of phased-array (PA) ultrasonic testing (UT) methods as applied to the inspection of welds in CASS pressurizer (PZR) surge line nuclear reactor piping. A set of thermal fatigue cracks (TFCs) was implanted into three CASS PZR surge-line specimens (pipe-to-elbow welds) that were fabricated using vintage CASS materials formed in the 1970s, and flaw responses from these cracks were used to evaluate detection and sizing performance of the PA-UT methods applied. This effort was comprised of multiple elements that included use of microstructural knowledge (dimensional analysis, grain orientation, and grain type) as well as sound field modeling to more effectively modify inspection parameters and enhance the inspection outcomes. Advanced probe design and sound field simulations were employed to enhance detection and characterization of circumferentially oriented flaws, and an assessment of lateral (circumferential) flaw localization capability and performance was also conducted. An evaluation of flaw detection, length sizing, depth sizing, and signal-to-noise ratio was performed for all flaws in the subject specimens, as a function of various inspection parameters, and finally, measurements were made to quantify and assess the baseline CASS material noise and its potential impact on flaw detection.
Diaz, Aaron A.; Cinson, Anthony D.; Crawford, Susan L.; Mathews, Royce; Moran, Traci L.; Anderson, Michael T.
U.S. Energy Information Administration (EIA) Indexed Site
ing the distribution of those galaxies, the way they clump and spread out, scientists
illuminated realms as small as a single molecule and as large as a gamma ray burst. of the Year Agony ex- plosions in the universe: titanic blasts of en- ergy called gamma ray bursts (GRBs). Most notably of black holes and other phenomena in the gamma ray region of the spectrum. And the Wilkinson Microwave
Yildiz, Ahmet
SUSTAINABILITY EXCELLENTIA CoLumbIA ENgINEErINg130
. Journal of "Solar Energy Materials and Solar Cells". Proceedings of IEEE Photovoltaic Specialist Conferences. Proceedings of European Photovoltaic Solar Energy Conferences. #12;Module 2/Photovoltaics, Wiley, 1995. R.H.Bube, Photovoltaic Materials, Imperial College Press, 1998. Journal of "Solar Energy
SUSTAINABILITY EXCELLENTIA CoLumbIA ENgINEErINg102
when carbon dioxide is introduced into thermal conversion processes such as the gasification of coal to syngas, leaving behind only a carbonless char. Castaldi estimates that if the biomass were used
Spring'ing' Forward Into the Finals . . . Of A Competition Like...
& Testimony Recovery Act Contact Information Office of Science U.S. Department of Energy 1000 Independence Ave., SW Washington, DC 20585 P: (202) 586-5430 03.11.13...
'March'ing Into The Finals . . . Of A Competition Like No Other
& Testimony Recovery Act Contact Information Office of Science U.S. Department of Energy 1000 Independence Ave., SW Washington, DC 20585 P: (202) 586-5430 03.04.13...
Power Electronics and Electrical Drives Prof. Dr.-Ing. Joachim Bcker
, e.g. Interior permanent magnet synchronous motors (IPMSM)Interior permanent magnet synchronous rings Permanent Magnet Synchronous Motor integrated into the rotor outlines Active magnetic bearing motors (IPMSM) Switched reluctance drives FPGA based control Self optimizing systems (Collaborative
Noé, Reinhold
Programme Coordination Professor Dr.-Ing. habil. Dr. h. c. Karl J. Thom-Kozmiensky
Waste Management · Recycling · Waste-to-Energy Recovery of Biowastes · Mechanical-Biological Treatment of the European Suppliers of Waste to Energy Technology (ESWET), Brussels, Belgium 10.30 Hrs. Waste Framework.V., Gent, Belgium 12.30 Hrs. Waste incineration in the 21st century Energy-efficient and climate
Hone, James
Wolfram Hoefer, Dr.-Ing. Assistant Professor Department of Landscape Architecture
Landentwicklung. Gärtner im Garten- und Landschaftsbau. (State exam for professional degree as gardener, landscape Ltd. London 1984-86 Apprenticeship as landscape gardener with Hermann Kretz, Garten und Landschaftsbau
Pico-ing into the future of mobile projection and contexts
Ten years ago, we were on the verge of having cameras built into our mobile phones, but knew very little about what to expect or how they would be used. Now we are faced with the same unknowns with mobile projector phones. This research seeks to explore ... Keywords: Diary study, Experience sampling, Mobile, Pico-projectors
Max L. Wilson; Dan Craggs; Simon Robinson; Matt Jones; Kristian Brimble
Koordination: Prof. Dr.-Ing. J. Seume Institut fr Turbomaschinen und Fluid-Dynamik
of installation of offshore wind farms (from Wiese 2008: Auswirkungen der Offshore-Windenergie auf den Betrieb von and offshore applications require appropriate planning and design. For most of them, statistics of extreme wind coastDat have been used in a large variety of coastal, offshore and terrestrial applications
Sandra Koch Dipl.-Ing. (FH) Telefon: 04921-807-1489
die Voraussetzung geschaffen, um die Stromerzeugung aus Windenergie Offshore langfristig erfolgreich geschaffen, um die Stromerzeugung aus Offshore Windenergie langfristig erfolgreich und effizient entwickeln-02 Bestimmung von Wärme- und Impulsfluss in der marinen atmosphärischen Grenzschicht für die Offshore
Damm, Werner
Annual Energy Outlook 2012 (EIA)
INFORMATION EXCELLENTIA CoLumbIA ENgINEErINg238
that bends and twists. "Computers, geometry, and physics are my ingredients. I mix them up in a bowl and what science as well. B.A.Sc., University of Toronto (Canada), 1997; M.S., California Institute of TechnologySPUn Associate Professor of Computer Science #12;
SUSTAINABILITY EXCELLENTIA CoLumbIA ENgINEErINg 141
- onry is also crucial to their safe storage. Plutonium, an active ingredient in nuclear weap- ons, has to determine how the electrons within these materials will behave. "The plutonium in the weapons ages, and we have to be able to predict the proper- ties of plutonium under a variety of conditions," Chris
Protective interior wall and attach8ing means for a fusion reactor vacuum vessel
An array of connected plates mounted on the inside wall of the vacuum vessel of a magnetic confinement reactor in order to provide a protective surface for energy deposition inside the vessel. All fasteners are concealed and protected beneath the plates, while the plates themselves share common mounting points. The entire array is installed with torqued nuts on threaded studs; provision also exists for thermal expansion by mounting each plate with two of its four mounts captured in an oversize grooved spool. A spool-washer mounting hardware allows one edge of a protective plate to be torqued while the other side remains loose, by simply inverting the spool-washer hardware.
Phelps, Richard D. (Greeley, CO); Upham, Gerald A. (Valley Center, CA); Anderson, Paul M. (San Diego, CA)
... bulky and heavy, expensive, fragile, short-range, sensitive to vibration, and unreliable for outdoor use in bright sunlight conditions. The ...
POTENTIAL APPLI ATIONS Parabolic dish & trough solar concentrating collectors Solar energy and renewable energy Electric utility
Kurzlebenslauf (CV) Stand September 2011 Dr.-Ing. Diplom-Physiker
:30 Panel: Erneuerbare Energien: Rentable Investitionen oder teure Experimente? Christof Stein (KfW Bank) Dr für Klima, Umwelt und Energie) Matthias Willenbacher (JuWi Holding) Moderation: Monika Seynsche
whITe PaPer The ChaNgINg DYNaMICS OF
of the smart grid, which integrates AMI with distribution automation and other tech- nologies to connect consumers Network Automation And Analytics Smart Meters Distributed Generation Today: Centralized and One smart grid and advanced metering deployments. Bob Brnilovich, IBM www.UtilitiesProject.com/10803
NOTIFICATION AND FEDERAL EMPLOYEE ANTIDISCRIMINATION AND NOTIFICATION AND FEDERAL EMPLOYEE ANTIDISCRIMINATION AND RETALIATION ACT (No FEAR Act) On March 3, 2011, Secretary Steven Chu issued a memorandum for all DOE employees, entitled "Equal Employment Opportunity and Diversity Policy Statement". In his policy statement, Secretary Chu expressed his commitment to equal employment opportunity and diversity, and his support of the rights of employees to participate in the EEO process without fear of reprisal. The Secretary's statement accords with the principles of the Notification and Federal Employee Antidiscrimination and Retaliation Act of 2002
Raw Materials and Casting Technology
Oct 11, 2010... steam turbine that would be operated in 700-760C steam conditions were tested. ... aerospace applications is a process that dates back about 80 years. ... Raising the temperature (primarily) and pressure (to a lesser extent)�...
Spray casting of metallic preforms
A metal alloy is melted in a crucible and ejected from the bottom of the crucible as a descending stream of molten metal. The descending stream is impacted with a plurality of primary inert gas jets surrounding the molten metal stream to produce a plume of atomized molten metal droplets. An inert gas is blown onto a lower portion of the plume with a plurality of auxiliary inert gas jets to deflect the plume into a more restricted pattern of high droplet density, thereby substantially eliminating unwanted overspray and resulting wasted material. The plume is projected onto a moving substrate to form a monolithic metallic product having generally parallel sides.
Flinn, John E. (Idaho Falls, ID); Burch, Joseph V. (Shelley, ID); Sears, James W. (Niskayuna, NY)
Casting Shadows in Real Time
Shadows are crucial for enhancing realism and provide important visual cues. In recent years, many important contributions have been made both for hard shadows and soft shadows. Often spurred by the tremendous increase of computational power and capabilities ...
Elmar Eisemann; Ulf Assarsson; Michael Schwarz; Michael Wimmer
PDF PRIMER: Investment Casting - TMS
Feb 15, 2007 ... This primer describes the basic process for producing superalloy components of complex shape, such as turbine blades and nozzle guide�...
Implementation of a Global Casthouse Furnace Energy Efficiency Program at Rio Tinto ... Optimised Re-melting by the Use of Low-temperature Oxyfuel at Hydro�...
UniCast, OutCast & GroupCast: Three Steps Toward Ubiquitous, Peripheral Displays
Artifacts and surfaces that can display digital content are proliferating at a steady rate. Many of these displays will be peripheral, i.e., used for content that is not directly related to one's primary activities. However, what kinds of content would ...
Joseph F. McCarthy; Tony J. Costa; Edy S. Liongosari
As-cast microstructures in U-Pu-Zr alloy fuel pins with 5-8 wt% minor actinides and 0-1.5 wt% rare-earth elements
The Idaho National Laboratory (INL) is investigating U�Pu�Zr alloys with low concentrations of minor actinides (Np and Am) and rare-earth elements (La, Ce, Pr, and Nd) as possible nuclear fuels to be used to transmute minor actinides. Alloys with compositions 60U�20Pu� 3Am�2Np�15Zr, 42U�30Pu�5Am�3Np�20Zr, 59U�20Pu�3Am�2Np�1RE�15Zr, 58.5U�20Pu� 3Am�2Np�1.5RE�15Zr, 41U�30Pu�5Am�3Np�1RE�20Zr, and 40.5U�30Pu�5Am�3Np�1.5RE� 20Zr (where numbers represent weight percents of each element and RE is a rare-earth alloy consisting of 6% La, 16% Pr, 25% Ce, and 53% Nd by weight) were arc-melted and vacuum cast as fuel pins approximately 4 mmin diameter. The as-cast pins were sectioned, polished, and examined by scanning electron microscopy. Each alloy contains high-Zr inclusions surrounded by a high-actinide matrix. Alloys with rare-earth elements also contain inclusions that are high in these elements. Within the matrix, concentrations of U and Zr vary inversely, while concentrations of Np and Pu appear approximately constant. Am occurs in the matrix and with some high-rare-earth inclusions, and occasionally as high-Am inclusions in samples without rare-earth elements.
Dawn E. Janney; J. Rory Kennedy
appg.vp:CorelVentura 7.0
1999 1999 (AEO99) are generated with the National Energy Modeling System (NEMS), developed and main- tained by the Office of Integrated Analysis and Fore- casting of the Energy Information Administration (EIA). In addition to its use in the development of the AEO projections, NEMS is also used in analyti- cal studies for the U.S. Congress and other offices within the Department of Energy. The AEO fore- casts are also used by analysts and planners in other government agencies and outside organizations. The projections in NEMS are developed with the use of a market-based approach to energy analysis. For each fuel and consuming sector, NEMS balances the energy supply and demand, accounting for the economic competition between the various energy fuels and sources. The time horizon of NEMS is the midterm period, approximately 20 years in the future. In order to represent the regional differences
As-cast microstructures in U-Pu-Zr alloy fuel pins with 5-8 wt.% minor actinides and 0- 1.5 wt% rare-earth elements
The Idaho National Laboratory (INL) is investigating U-Pu-Zr alloys with low concentrations of minor actinides (Np, Am) and rare-earth elements (La, Ce, Pr, Nd) as possible nuclear fuels to be used to transmute minor actinides. Alloys with compositions 60U-20Pu-3Am-2Np-15Zr, 42U-30Pu-5Am-3Np-20Zr, 59U-20Pu-3Am-2Np-1RE-15Zr, 58.5U-20Pu-3Am-2Np-1.5RE-15Zr, 41U-30Pu-5Am-3Np-1RE-20Zr, and 40.5U-30Pu-5Am-3Np-1.5RE-20Zr (where numbers represent weight percents of each element and RE is a rare-earth alloy consisting of 6% La, 16% Pr, 25% Ce, and 53% Nd by weight) were arc-melted and vacuum cast as fuel pins approximately 4 mm in diameter. The pins were sectioned, polished, and examined by scanning electron microscopy. Each alloy contains high-Zr inclusions surrounded by a high-actinide matrix. Alloys with lanthanides also contain high-RE inclusions. Within the matrix, concentrations of U and Zr vary inversely, while concentrations of Np and Pu appear approximately constant. Am occurs in the matrix and with some high-RE inclusions, and occasionally as high-Am inclusions in samples without REs.
FORE-Watch � the clock that tells you when to use: persuading users to align their energy consumption with green power availability
Besides saving energy, using it at the right time (i.e. when there is a supply surplus, and the power is produced by sustainable power sources such as hydroelectricity or wind) is an important possibility to achieve positive effects for the environment. ... Keywords: ambient display, eco-feedback, persuasion, user-centered design
Johann Schrammel; Cornelia Gerdenitsch; Astrid Weiss; Patricia M. Kluckner; Manfred Tscheligi
Wherestudentsbecomeengineers... andsomethingmore
, and testing needs of the rapidly expand- ing wind energy industry. www.engineering.uiowa.edu/ economic cells; produce better steel castings; or improve devices that utilize alternative energy sources. iowa and Computer 16-17 ........Industrial 18-19 .......Mechanical 20-21 .......Beyond the Classroom 22
Engelhardt, John F.
Institutsleitung: Univ.-Prof. Dr.-Ing. Prof. E.h. Dr.-Ing. E.h. Dr. h.c. mult. Engelbert Westkmper Kontakt: Birgit Spaeth Presse-und ffentlichkeitsarbeit
Universitätsprofessor ernannt wird. Thomas Bauernhansl, 1969 im fränkischen Miltenberg geboren, hat Maschinenbau an der
Möbius, Bernd
Technical Report Documentation Page 1. Report No.
.-Ing. Biljana Milivojevic Dipl.-Ing. Vitali Mirvoda Stip. Dipl.-Ing. Timo Pfau Dr.-Ing. David Sandel Dr
The Burning Man festival is a unique happen-ing. For one week in September every year,
spaces, the city as it alters over the seven days and from year to year, exhibiting emergent properties- ance of oversized gas-guzzling camper vans, fossil-fuel-powered generators and gratuitous combustion, it is no Utopia. But the City's Alternative Energy Zone, with its huge bank of solar panels, multiple experiments
Bourne, Philip E.
58 UTS ANNUAL REPORT 2008 sUppoRtING oUR objEctIvEs
improvingenvironmentalsustainabilityin ourcampusoperations.Itisoverseenby asteeringcommitteeandsevenworking groups:waste,transport,energy into the atmosphere. The proposal from students Antony Henry and Kavit Pandya was to put this wasted energy through Energy-efficientlightinginmorethan> 60percentoftheUniversity Savingtheequivalentof45Olympic
University of Technology, Sydney
Tactical urbanism, public policy reform, and 'innovation spotting' by government : from Park(ing) Day to San Francisco's parklet program
This thesis examines the prospects and impacts of tactical urbanism (TU). While tactical urbanism remains primarily a subcultural movement, it is beginning to gain traction in popular culture in traditionally politically ...
Davidson, Mariko Mura
Cultivat(ing) modernities : the Society for National Heritage, political propaganda and public architecture in twentieth-century Iran
Beginning in 1922, under the auspices of the Pahlavi dynasty of Iran, the tombs of selected historical figures were systematically destroyed to make way for modern mausoleums erected as metaphors for an "Aryan" nation in ...
Grigor, Talinn, 1972-
Laboratories which led to the use of acid tests such as the EP and TCLP tests. [25] 13 #12;CONCLUSIONS and soluble metals in the ash from Waste-to Energy (WTE) facilities has led to a public concern about why has led to the requirement for continuous monitoring of oxygen , carbon monoxide (CO) , and acid gases
Columbia University
Friction Stir Processing of Cast Superalloys
... Corrosion Inhibition for Hydrochloric Acid Pickling � Using Resistance Heating to Create Full-Scale API RP2Z CTOD Samples�...
Contents Casting Coupling / Multi-physics
3. Cyclone-Based System for Cleaning Liquid Aluminum of Solid Inclusions: Numerical Study. Laurens Katgerman; Dmitry G. Eskin; Andrey N. Turchin.
Casting of the WAM as an EAM
Logic programming provides a very high-level view of programming, which comes at the cost of some execution efficiency. Improving performance of logic programs is thus one of the holy grails of Prolog system implementations and a wide range of approaches have historically been taken towards this goal. Designing computational models that both exploit the available parallelism in a given application and that try hard to reduce the explored search space has been an ongoing line of research for many years. These goals in particular have motivated the design of several computational models, one of which is the Extended Andorra Model (EAM). In this paper, we present a preliminary specification and implementation of the EAM with Implicit Control, the WAM2EAM, which supplies regular WAM instructions with an EAM-centered interpretation.
Andr�, Paulo
Autonomous Directional Solidification (ADS), A Novel Casting ...
the enormous production costs, alternative processes attract special interest. At the Foundry-Institute of the Technical University of. Aachen, the Autonomous�...
Flow and Solidification Modeling of Al Castings
Readings were data logged into a computer at a rate of 50 per second. ... to the ingate and not that at the geometric center of the plate, which illustrated a useful�...
Numerical Modeling of Centrifugally Cast HSS Rolls
This model will help to further understand the complex solidification behavior of the HSS roll. Performance of the HSS roll requires proper formation and�...
The Gendering of Film and Television Casting
workers. In the case of the Edison stu- dios in New Jersey,staff were transferred from the Edison business headquartersto the Edison studio where, "New offices are being built
Hill, Erin
Effects of Heat Treatment and Casting Process
Feb 17, 2010 ... Ca Alloys: Keiichiro Oh-ishi1; Chamini Mendis1; Ryuichi Watanabe2; Kazuhiro Hono1; 1National Institute for Materials Science; 2Graduate�...
Liquid Metal Processing and Casting 2013
Ceramic, Slag and Refractory Reactions with Liquid Metals - Refining, Evaporation and Gas/Metal Reactions - Fundamentals of Reactions involving Liquid�...
Solidification Modeling of Alloy 718 Structural Castings
phenomena such as heat transfer, fluid flow, thermal stress, microstructure ... For convenience, rectangular instead of circular cross-sections were used for the�...
Cast Stone Waste Form � Development & Optimization
14 Sodium fluoride Sodium fluoride Sodium fluoride 15 Sodium dichromate Sodium dichromate Sodium dichromate 16 Sodium iodide Sodium iodide Sodium iodide
Green Slag System Design during Continuous Casting
Cellulose Acetate Membranes for CO2 Separation from Water-gas-shift Reaction ... Thermodynamic Phase Stability in Gasification Carbon Feedstock Slags�...
Defects and Properties of Cast Metals
Conference Tools for 2012 TMS Annual Meeting & Exhibition ... In many instances the mechanism for the generation of the defects arises from a combination of�...
CAST ALUMINA FORMING AUSTENITIC STAINLESS STEELS - Energy ...
Wind Energy; Partners (27) Visual Patent Search; Success Stories; News; Events; ... and a stable essentially single phase FCC austenitic matrix microstructure, ...
Powder Metallurgy and Spray Casting - TMS
Use this area to submit digital resources and/or make comments on the resources posted by others. DO NOT use this area of the site to initiate discussion �...
Advances in Metal Casting Technologies: Aluminum
... Deposition of Thin Films via Sputtering: Ulises Barajas1; Sugeily Flores- Bonano,1; Ver�nica Santiago-Torres1; O. Marcelo Su�rez1; 1University of Puerto Rico
Cast alumina forming austenitic stainless steels
An austenitic stainless steel alloy consisting essentially of, in terms of weight percent ranges 0.15-0.5C; 8-37Ni; 10-25Cr; 2.5-5Al; greater than 0.6, up to 2.5 total of at least one element selected from the group consisting of Nb and Ta; up to 3Mo; up to 3Co; up to 1W; up to 3Cu; up to 15Mn; up to 2Si; up to 0.15B; up to 0.05P; up to 1 total of at least one element selected from the group consisting of Y, La, Ce, Hf, and Zr; <0.3Ti+V; <0.03N; and, balance Fe, where the weight percent Fe is greater than the weight percent Ni, and wherein the alloy forms an external continuous scale comprising alumina, and a stable essentially single phase FCC austenitic matrix microstructure, the austenitic matrix being essentially delta-ferrite free and essentially BCC-phase-free. A method of making austenitic stainless steel alloys is also disclosed.
Muralidharan, Govindarajan; Yamamoto, Yukinori; Brady, Michael P
Limited Casting Resources Meet World Class Ingenuity
This consisted of the adaptation of a drum-type blower fan taken from a discarded truck heater system. It was driven at high speed by a gasoline engine of a�...
Aluminum Cast Shop II - Programmaster.org
Mar 5, 2013 ... Advanced Compact Filter: ( ACF) An Efficient and Flexible Filtration Process: Francis Breton1; Peter Waite1; Patrice Robichaud1; 1Rio Tinto�...
Casting, Surface Modification, and Powder Processing
Mar 3, 2011 ... The graphite particles also reduce significantly the oil absorption without ... increases sharply with the increase of peak value of electric current;�...
Cooling system for continuous metal casting machines
A continuous metal caster cooling system is provided in which water is supplied in jets from a large number of small nozzles against the inner surface of rim at a temperature and with sufficient pressure that the velocity of the jets is sufficiently high that the mode of heat transfer is substantially by forced convection, the liquid being returned from the cooling chambers through return pipes distributed interstitially among the nozzles. 9 figs.
Draper, R.; Sumpman, W.C.; Baker, R.J.; Williams, R.S.
A continuous metal caster cooling system is provided in which water is supplied in jets from a large number of small nozzles 19 against the inner surface of rim 13 at a temperature and with sufficient pressure that the velocity of the jets is sufficiently high that the mode of heat transfer is substantially by forced convection, the liquid being returned from the cooling chambers 30 through return pipes 25 distributed interstitially among the nozzles.
Draper, Robert (Churchill Boro, PA); Sumpman, Wayne C. (North Huntingdon, PA); Baker, Robert J. (Wilkins Township, Allegheny County, PA); Williams, Robert S. (Plum Borough, PA)
Silicon cast wafer recrystallization for photovoltaic applications
Current industry-standard methods of manufacturing silicon wafers for photovoltaic (PV) cells define the electrical properties of the wafer in a first step, and then the geometry of the wafer in a subsequent step. The ...
Hantsoo, Eerik T. (Eerik Torm)
Steelmaking and Casting II - Programmaster.org
Oct 30, 2013 ... 8:00 AM Analysis of Residence Time Distribution (RTD) of Fluid Flows in a Four Strand Delta-shaped Tundish Operating Under Isothermal and�...
Porosity in Cast Equiaxed Alloy 718
techniques and the total percentage of porosity across each lmm wide band through ... Figure 3 shows the average percentage porosity as a function of position�...
CAST SHOP TECHNOLOGY: I: Fundamentals and Modelling
By combining different techniques the energy dissipation in the reactor, the mass ... Arild H�konsen, Hydro Aluminium R&D Materials Technology, P.O.Box 219,�...
Total Space Heat-
Released: September, 2008 Total Space Heat- ing Cool- ing Venti- lation Water Heat- ing Light- ing Cook- ing Refrig- eration Office Equip- ment Com- puters Other All Buildings...
Revised: December, 2008 Total Space Heat- ing Cool- ing Venti- lation Water Heat- ing Light- ing Cook- ing Refrig- eration Office Equip- ment Com- puters Other All Buildings*...
Released: September, 2008 Total Space Heat- ing Cool- ing Venti- lation Water Heat- ing Light- ing Cook- ing Refrig- eration Office Equip- ment Com- puters Other All Buildings*...
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Intensity (thousand Btusquare foot) Total Space Heat- ing Cool- ing Venti- lation Water Heat- ing Light- ing Cook- ing Refrig- eration Office Equip- ment Com- puters Other...
Revised: December, 2008 Total Space Heat- ing Cool- ing Venti- lation Water Heat- ing Light- ing Cook- ing Refrig- eration Office Equip- ment Com- puters Other All Buildings...
Electricity Consumption (trillion Btu) Total Space Heat- ing Cool- ing Venti- lation Water Heat- ing Light- ing Cook- ing Refrig- eration Office Equip- ment Com- puters Other...
Major Fuel Consumption (trillion Btu) Total Space Heat- ing Cool- ing Venti- lation Water Heat- ing Light- ing Cook- ing Refrig- eration Office Equip- ment Com- puters Other...
SmartCast - Novel Textile Sensors for Embedded Pressure Sensing of Orthopedic Casts
e.g. polyester w/ woven carbon fibers or Velostat Layer 4.of polyester with woven carbon fibers, and Layer 5 has beenthan polyester with carbon fibers. Conductive thread was
Danilovic, Andrew
SmartCast: Instrumented Casts for Monitoring and Intervention during Bone Healing Process
with a diamond pattern of carbon fibers providing surfaceIt is 87% polyester with 13% carbon fibers woven into it.The carbon fibers are conducting [29]. The Velostat is a
Shahbazi, Maryam
Clemson University Preservation master Plan Part III: ExIstIng CondItIons ChaPtEr Four FEbruary 2009 JMa, InC. 70
,337 CFDA # 15.922 - Native American Graves Protection and Repatriation Act Direct Federal Awards 16,227 525,830 - 4,830 Lawrence Berkeley Natl Lab RF HANFORD SEDM THOMP-6875736 48,614 2,965 45,649 Savannah River Nuclear Solutns RF RIVERBASIN GRUND-AC716760 132,105 9,248 122,857 Savannah River Nuclear Solutns RF SUP
Stuart, Steven J.
Evaluation of the carbon content of aerosols from the burn- ing of biomass in the Brazilian Amazon using thermal, op- tical and thermal-optical analysis methods
Tar Balls from Smoldering Biomass Combustion. Atmos. Chem.gases and particles from biomass burning in Brazil, J. Ge-for smoke from African biomass burning, J. Geophys. Res. ,
Soto-Garcia, Lydia L.
MICRO-MACHINED THIN FILM HYDROGEN GAS SENSORS Frank DiMeo, Jr., Ing-Shin Chen, Philip Chen, Jeffrey Neuner
;Introduction The reputation of hydrogen as the next generation energy delivery agent, supplementing electricity of Electric Power Research Institute, in a recent The Industrial Physicist column, observed the multifaceted as a national security priority. While fuel cell cars often feature prominently in news media and are touted
2001. Kerminen, V. -M. , Makela, T. E. , Ojanen, C. H. ,Saarikoski, S. , Frey, A. , M�kel�, T. , and Hillamo, R. :Acker, K. , Hillamo, R. , M�kel�, T. : Intercomparison of
Early and sustained interventions which strongly feature mentoring are essential in help-ing Native American and Latino students navigate an unfamiliar academic system that is
(Navajo) is the largest, with 170,000 members. Others include the Oglala Sioux, Cherokee Nation, Blackfeet
Benitez-Nelson, Claudia
Shai Agassi's story of his evolving personal interest in energy issues, and the evolv-ing business plan of his electric vehicle company, Better Place, provides an impor-
uncer- tainty over battery costs, battery charging standards, and battery technology that will surely
Kammen, Daniel M.
Aerosol samples were collected at a pasture site in the Amazon Basin as part of the project LBA-SMOCC-2002 (Large-Scale Biosphere-Atmosphere Experiment in Amazonia - Smoke Aerosols, Clouds, Rainfall and Climate: Aerosols from Biomass Burning Perturb Global and Regional Climate). Sampling was conducted during the late dry season, when the aerosol composition was dominated by biomass burning emissions, especially in the submicron fraction. A 13-stage Dekati low-pressure impactor (DLPI) was used to collect particles with nominal aerodynamic diameters (D{sub p}) ranging from 0.03 to 0.10 m. Gravimetric analyses of the DLPI substrates and filters were performed to obtain aerosol mass concentrations. The concentrations of total, apparent elemental, and organic carbon (TC, EC{sub a}, and OC) were determined using thermal and thermal-optical analysis (TOA) methods. A light transmission method (LTM) was used to determine the concentration of equivalent black carbon (BC{sub e}) or the absorbing fraction at 880 nm for the size-resolved samples. During the dry period, due to the pervasive presence of fires in the region upwind of the sampling site, concentrations of fine aerosols (D{sub p} < 2.5 {mu}m: average 59.8 {mu}g m{sup -3}) were higher than coarse aerosols (D{sub p} > 2.5 {mu}m: 4.1 {mu}g m{sup -3}). Carbonaceous matter, estimated as the sum of the particulate organic matter (i.e., OC x 1.8) plus BC{sub e}, comprised more than 90% to the total aerosol mass. Concentrations of EC{sub a} (estimated by thermal analysis with a correction for charring) and BCe (estimated by LTM) averaged 5.2 {+-} 1.3 and 3.1 {+-} 0.8 {mu}g m{sup -3}, respectively. The determination of EC was improved by extracting water-soluble organic material from the samples, which reduced the average light absorption {angstrom} exponent of particles in the size range of 0.1 to 1.0 {mu}m from > 2.0 to approximately 1.2. The size-resolved BC{sub e} measured by the LTM showed a clear maximum between 0.4 and 0.6 m in diameter. The concentrations of OC and BC{sub e} varied diurnally during the dry period, and this variation is related to diurnal changes in boundary layer thickness and in fire frequency.
Soto-Garcia, Lydia L.; Andreae, Meinrat O.; Andreae, Tracey W.; taxo, Paulo Ar-; Maenhaut, Willy; Kirchstetter, Thomas; Novakov, T.; Chow, Judith C.; Mayol-Bracero, Olga L.
CS-03-02 A PIvotIng PRocEDuRE FoR A ClAss oF SEconD-oRDER ...
linear function over an intersection of an affine set and second-order cones. SOCP is a .... Note that the e q uality constraints of ����� does not contain�!7# .
Crutzen, P. : Atmospheric Aerosols: Biogeochemical sourcesof optically active aerosol particles over the Amazonproperties of Amazonian aerosol particles: Rev. Geophys. ,
Aerosol samples were collected at a pasture site in the Amazon Basin as part of the project LBA-SMOCC-2002 (Large-Scale Biosphere-Atmosphere Experiment in Amazonia - Smoke Aerosols, Clouds, Rainfall and Climate: Aerosols from Biomass Burning Perturb Global and Regional Climate). Sampling was conducted during the late dry season, when the aerosol composition was dominated by biomass burning emissions, especially in the submicron fraction. A 13-stage Dekati low-pressure impactor (DLPI) was used to collect particles with nominal aerodynamic diameters (D{sub p}) ranging from 0.03 to 0.10 m. Gravimetric analyses of the DLPI substrates and filters were performed to obtain aerosol mass concentrations. The concentrations of total, apparent elemental, and organic carbon (TC, EC{sub a}, and OC) were determined using thermal and thermal-optical analysis (TOA) methods. A light transmission method (LTM) was used to determine the concentration of equivalent black carbon (BC{sub e}) or the absorbing fraction at 880 nm for the size-resolved samples. During the dry period, due to the pervasive presence of fires in the region upwind of the sampling site, concentrations of fine aerosols (D{sub p} aerosols (D{sub p} > 2.5 {mu}m: 4.1 {mu}g m{sup -3}). Carbonaceous matter, estimated as the sum of the particulate organic matter (i.e., OC x 1.8) plus BC{sub e}, comprised more than 90% to the total aerosol mass. Concentrations of EC{sub a} (estimated by thermal analysis with a correction for charring) and BCe (estimated by LTM) averaged 5.2 {+-} 1.3 and 3.1 {+-} 0.8 {mu}g m{sup -3}, respectively. The determination of EC was improved by extracting water-soluble organic material from the samples, which reduced the average light absorption {angstrom} exponent of particles in the size range of 0.1 to 1.0 {mu}m from > 2.0 to approximately 1.2. The size-resolved BC{sub e} measured by the LTM showed a clear maximum between 0.4 and 0.6 m in diameter. The concentrations of OC and BC{sub e} varied diurnally during the dry period, and this variation is related to diurnal changes in boundary layer thickness and in fire frequency.
from Smoldering Biomass Combustion. Atmos. Chem. Phys. , 10,aerosols emitted during biomass combustion [Robinson et al.burning samples. Combustion of biomass produces EC a and
Taipei terminal rail station : casting an urban gateway
Access is a key issue in the design of railway stations. The evolution of the train station typology, has resulted in many types of stations based on the development of the stations' access. Since rail travel on a larger ...
Tsai, May Deanna
Microcast-X Fine Grain Casting - A Progress Report
showed this treatment solutioned both the Laves and delta phases. Final preparation for forging included preform grinding to remove sharp edges, shot blasting.
Residual Stress Determination in Cast Bi-Metallic Joints
In-Situ Neutron Diffraction and Crystal Plasticity Modeling of a-Uranium � In-Situ Studies of the ... Thermal Residual Stresses and Strains in Depleted Uranium.
analysis of casting defects in magnesium � aluminium � zinc direct ...
Jul 20, 2012 ... If the price of this product displays as $0.00 for your customer category, you may download it for free. You must, however, add it to your cart and�...
DEVELOPMENT OF Mg-Si BASED CAST ALLOYS
Low Cost Processing: Plasma, Microwave, Laser, Melting and Casting
Mar 5, 2013 ... Cost Affordable Titanium IV: Low Cost Processing: Plasma, ... obtained by using microwave energy as the consolidation method of Mg-Ti alloys.
Economic Cast Study: The Impact of NSTIC on the Internal ...
... a broad government initiative driven by the Federal CIO Council that aims ... A memorandum issued by the Federal Chief Information Officer in 2011 ...