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Sabau, Adrian S

Publications and source records attributed to Sabau, Adrian S.

13 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Hot-tearing of multicomponent Al-Cu alloys based on casting load measurements in a constrained permanent mold

Hot-tearing is a major casting defect that is often difficult to characterize, especially for multicomponent Al alloys used for cylinder head castings. The susceptibility of multicomponent Al-Cu alloys to hot-tearing during permanent mold casting was investigated using a constrained permanent mold in which the load and displacement was measured. The experimental results for hot tearing susceptibility are compared with those obtained from a hot-tearing criterion based temperature range evaluated at fraction solids of 0.87 and 0.94. The Cu composition was varied from approximately 5 to 8 pct. (weight). Casting experiments were conducted without grain refining. The measured load during casting can be used to indicate the severity of hot tearing. However, when small hot-tears are present, the load variation cannot be used to detect and assess hot-tearing susceptibility.

Sabau, Adrian S↗
DOE OSTI2016

Multi-scale evaporator architectures for geothermal binary power plants

In this paper, novel geometries of heat exchanger architectures are proposed for evaporators that are used in Organic Rankine Cycles. A multi-scale heat exchanger concept was developed by employing successive plenums at several length-scale levels. Flow passages contain features at both macro-scale and micro-scale, which are designed from Constructal Theory principles. Aside from pumping power and overall thermal resistance, several factors were considered in order to fully assess the performance of the new heat exchangers, such as weight of metal structures, surface area per unit volume, and total footprint. Component simulations based on laminar flow correlations for supercritical R134a were used to obtain performance indicators.

Sabau, Adrian S↗
DOE OSTI2016

Exfoliation Propensity of Oxide Scale in Heat Exchangers Used for Supercritical CO2 Power Cycles

Supercritical CO2 (sCO2) Brayton cycle systems offer the possibility of improved efficiency in future fossil energy power generation plants operating at temperatures of 650 C and above. As there are few data on the oxidation/corrosion behavior of structural alloys in sCO2 at these temperatures, modeling to predict the propensity for oxide exfoliation is not well developed, thus hindering materials selection for these novel cycles. The ultimate goal of this effort is to provide needed data on scale exfoliation behavior in sCO2 for confident alloy selection. To date, a model developed by ORNL and EPRI for the exfoliation of oxide scales formed on boiler tubes in high-temperature, high-pressure steam has proven useful for managing exfoliation in conventional steam plants. A major input provided by the model is the ability to predict the likelihood of scale failure and loss based on understanding of the evolution of the oxide morphologies and the conditions that result in susceptibility to exfoliation. This paper describes initial steps taken to extend the existing model for exfoliation of steam-side oxide scales to sCO2 conditions. The main differences between high-temperature, high-pressure steam and sCO2 that impact the model involve (i) significant geometrical differences in the heat exchangers, ranging from standard pressurized tubes seen typically in steam-producing boilers to designs for sCO2 that employ variously-curved thin walls to create shaped flow paths for extended heat transfer area and small channel cross-sections to promote thermal convection and support pressure loads; (ii) changed operating characteristics with sCO2 due to the differences in physical and thermal properties compared to steam; and (iii) possible modification of the scale morphologies, hence properties that influence exfoliation behavior, due to reaction with carbon species from sCO2. The numerical simulations conducted were based on an assumed sCO2 operating schedule and several generic heat exchanger channel shapes and cross-sectional areas. Implications for the evolution of stresses in the oxide scales formed on sCO2 heat exchangers, and ensuing critical oxide thicknesses for exfoliation, were derived and compared with expectations for an equivalent conventional tubular heat exchanger in a steam cycle (for a given alloy).

Sabau, Adrian S↗
DOE OSTI2016

A LASER INTERFERENCE-BASED SURFACE TREATMENT OF AL AND CARBON FIBER POLYMER COMPOSITES FOR ENHANCED BONDING

Due to its increased use in the automotive and aerospace industries, joining of Carbon Fiber-reinforced Polymer matrix Composites (CFPC) to metals demands enhanced surface preparation and control of surface morphology prior to joining. In this study, surfaces of both composite and aluminum were prepared for joining using a new laser based technique, in which the laser interference power profile was created by splitting the beam and guiding those beams to the sample surface by overlapping each other with defined angles to each other. Results were presented for the overlap shear testing of single-lap joints made with Al 5182 and CFPC specimens whose surfaces prepared by (a) surface abrasion and solvent cleaning; and (b) laser-interference structured surfaces by rastering with a 4 mm laser beam at approximately 3.5 W power. CFPC specimens of T700S carbon fiber, Prepreg T70 epoxy, 4 or 5 ply thick, 0/90o plaques were used. Adhesive DP810 was used to bond Al and CFPC. The bondline was 0.25mm and the bond length was consistent among all joints produced. First, the effect of the laser speed on the joint performance was evaluated by laser-interference structure Al and CFPC surfaces with a beam angle of 3o and laser beam speeds of 3, 5, and 10 mm/s. For this sensitivity study, 3 joint specimens were used per each joint type. Based on the results for minimum, maximum, and mean values for the shear lap strength and maximum load for all the 9 joint types, two joint types were selected for further evaluations. Six additional joint specimens were prepared for these two joint types in order to obtain better statistics and the shear test data was presented for the range, mean, and standard deviation. The results for the single-lap shear tests obtained for six joint specimens, indicate that the shear lap strength, maximum load, and displacement at maximum load for those joints made with laser-interference structured surfaces were increased by approximately 14.8%, 16%, and 100%, respectively over those measured for the baseline joints.

Sabau, Adrian S↗
DOE OSTI2015

SURFACE MORPHOLOGY OF CARBON FIBER POLYMER COMPOSITES AFTER LASER STRUCTURING

The increasing use of Carbon Fiber Polymer Composite (CFPC) as a lightweight material in automotive and aerospace industries requires the control of surface morphology. In this study, the composites surface was prepared by ablating the resin in the top fiber layer of the composite using an Nd:YAG laser. The CFPC specimens with T700S carbon fiber and Prepreg - T83 resin (epoxy) were supplied by Plasan Carbon Composites, Inc. as 4 ply thick, 0/90o plaques. The effect of laser fluence, scanning speed, and wavelength was investigated to remove resin without an excessive damage of the fibers. In addition, resin ablation due to the power variation created by a laser interference technique is presented. Optical property measurements, optical micrographs, 3D imaging, and high-resolution optical profiler images were used to study the effect of the laser processing on the surface morphology.

Sabau, Adrian S↗
DOE OSTI2015

Aluminum Surface Texturing by Means of Laser Interference Metallurgy

The increasing use of lightweight materials, such as aluminum alloys, in auto body structures requires more effective surface cleaning and texturing techniques to improve the quality of the structural components. The present work introduces a novel surface treatment method using laser interferometry produced by two beams of a pulsed Nd:YAG laser operating at 10Hz of frequency to clean aluminum surfaces, and meanwhile creating periodic and rough surface structures. The influences of beam size, laser fluence, wavelength, and pulse number per spot are investigated. High resolution optical profiler images reveal the change of the peak-to-valley height on the laser-treated surface.

Chen, Jian↗
DOE OSTI2015

CASTING DEFECT MODELING IN AN INTEGRATED COMPUTATIONAL MATERIALS ENGINEERING APPROACH

To accelerate the introduction of new cast alloys, the simultaneous modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components. The required models related to casting defects, such as microporosity and hot tears, are reviewed. Three aluminum alloys are considered A356, 356 and 319. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Examples are given for predicting microporosity defects and microstructure distribution for a plate casting. Models to predict fatigue life and yield stress are briefly highlighted here for the sake of completion and to illustrate how the length scales of the microstructure features as well as porosity defects are taken into account for modeling the mechanical properties. Thus, the data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. ACKNOWLEDGEMENTS This work was performed under a Cooperative Research and Development Agreement (CRADA) with the Nemak Inc., and Chrysler Co. for the project "High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines. The author would also like to thank Amit Shyam for reviewing the paper and Andres Rodriguez of Nemak Inc. Research sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Office, as part of the Propulsion Materials Program under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Part of this research was conducted through the Oak Ridge National Laboratory's High Temperature Materials Laboratory User Program, which is sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Program.

Sabau, Adrian S↗
DOE OSTI2014

Facility for high heat flux testing of irradiated fusion materials and components using infrared plasma arc lamps

A new high-heat flux testing facility using water-wall stabilized high-power high-pressure argon Plasma Arc Lamps (PALs) has been developed for fusion applications. It can handle irradiated plasma facing component materials and mock-up divertor components. Two PALs currently available at ORNL can provide maximum incident heat fluxes of 4.2 and 27 MW/m2 over a heated area of 9x12 and 1x10 cm2, respectively, which are fusion-prototypical steady state heat flux conditions. The facility will be described and the main differences between the photon-based high-heat flux testing facilities, such as PALs, and the e-beam and particle beam facilities more commonly used for fusion HHF testing are discussed. The components of the test chamber were designed to accommodate radiation safety and materials compatibility requirements posed by high-temperature exposure of low levels irradiated tungsten articles. Issues related to the operation and temperature measurements during testing are presented and discussed.

Sabau, Adrian S↗
DOE OSTI2014

MANAGING OXIDE SCALE EXFOLIATION IN BOILERS WITH TP347H SUPERHEATER TUBES

A model based on a concept of fraction of exfoliated area as a function of oxide scale strain energy was developed to predict the extent of exfoliation of steam-side scale from boiler tube superheater loops. As compared with the Armitt diagram, which can be used to predict when scale damage and exfoliation would be likely to occur, a fraction of exfoliated area approach provides an estimation of mass of scale released and the fraction of tube likely to be blocked by the exfoliation. This paper show results for the extent of blockage expected in a single bend of a superheater loop was predicted as a function of operating time, bend geometry, and outlet steam temperature under realistic service conditions that include outages. The deposits of exfoliated scale were assumed to be distributed horizontally the tubes bends. Three types of bends were considered: regular bends, short bends, and hairpin bends. The progressive increase in steam and tube temperatures along a single loop of superheater tubing and the ensuing variation of oxide scale thickness are considered. Numerical simulation results for a superheater loop made of TP347H austenitic steel indicated that tube blockage fractions larger than 50% are likely to occur within the first two years of boiler operation (with regularly scheduled outages) for outlet tube temperatures of 540-570oC, which is consistent with practical experience. Higher blockage fractions were predicted for tubes with short bends and hairpin bends than for tubes with regular bends, of length that are larger than five internal tube diameters. Finally, the blockage model presented can be used with some confidence to devise operating schedules for managing the consequences of oxide scale exfoliation based on projections of time to some critical blockage fraction for specific boiler operating conditions.

Sabau, Adrian S↗
DOE OSTI2014

Process Simulation Role in the Development of New Alloys Based on Integrated Computational Material Science and Engineering

To accelerate the introduction of new materials and components, the development of metal casting processes requires the teaming between different disciplines, as multi-physical phenomena have to be considered simultaneously for the process design and optimization of mechanical properties. The required models for physical phenomena as well as their validation status for metal casting are reviewed. The data on materials properties, model validation, and relevant microstructure for materials properties are highlighted. One vehicle to accelerate the development of new materials is through combined experimental-computational efforts. Integrated computational/experimental practices are reviewed; strengths and weaknesses are identified with respect to metal casting processes. Specifically, the examples are given for the knowledge base established at Oak Ridge National Laboratory and computer models for predicting casting defects and microstructure distribution in aluminum alloy components.

Sabau, Adrian S↗