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At least 199 records · Page 11

Elevated temperature tensile tests on DU–10Mo rolled foils

We report that studies were completed to obtain tensile mechanical properties for uranium-10wt.% molybdenum (U-10Mo) foils which were subjected to four different thermomechanical processing conditions. U-Mo alloy foils are being investigated to support fuel conversion of high power research reactors from their current high enriched fuel form to a low enriched fuel form. Mechanical properties of the fuel foil have an effect on irradiation performance and fuel fabrication and therefore are required to support modeling and qualification of new low-enriched uranium monolithic fuel plate designs. The data contained in this document contributes to fuel qualification by fulfilling the requirement that physical properties related to fuel meat be established. It is expected that depleted uranium-10wt% Mo (DU–10Mo) mechanical behavior is representative of the low-enriched U10-Mo to be used in actual fuel plates; therefore DU–10Mo was studied to simplify material processing, handling, and testing requirements. In this report, the different thermomechanical treatments included variations of wrought hot and cold rolling reduction and post rolling annealing. Each of the four foils was hot rolled. After hot rolling reduction, three of the four foils were further reduced by cold rolling. One of the three was reduced a further 20% by cold rolling, and the remaining two were reduced 50% by cold rolling. Following cold rolling reduction, one of the two foils which had been reduced 50% by cold rolling was annealed at 650?°C. Performing this analysis allows assessment of the impact of foil fabrication history on the resultant tensile properties DU–10Mo fuel foils. Tensile properties of DU–10Mo at room temperature through approximately 400 °C determined from the tests conducted herein suggest the material is stronger and has lower ductility than what has been reported previously in the literature. The explanation for these differences has yet to be determined, but is likely related to differences in grain size and/or impurity content, and variation in fabrication history. At the highest temperatures tested (550 °C) better agreement between the values reported here and available literature was found. As expected, yield and ultimate tensile strength decreased with increasing test temperature. Generally, the yield stress for all foil processing conditions was found to be in the range of 1100 MPa for room temperature tests, and in the range of 200 MPa for tests conducted at 550 °C. Ultimate tensile stress was in the range of 1175 MPa at room temperature, decreasing to approximately 225 MPa at 550 °C. Lastly, elongation increased significantly, from 0 to 2% at room temperature to 50% or more for the tests at 550 °C.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Carbide Particle Redistribution in U-10Mo Alloy during Hot and Cold Rolling Processes: Synthetic Microstructure-Based Finite-Element Approach

The influence of initial carbide particle distribution features on particle fracture and the evolution of stringer distribution within an alloy of uranium with 10 weight percent molybdenum during cold rolling was investigated in this study. This work will provide guidance to casting optimization work and identify actionable process changes to eliminate the surface features directly attributed to carbides. In a previous study, various synthetic microstructure-based finite-element (FE) models were generated with consideration of different parameters (i.e., particle shape, particle volume fraction, and particle distribution), and used to examine the effects of hot rolling on the microstructure evolution. In this study, microstructures after ~80% hot rolling were used as the initial microstructures for the subsequent cold rolling simulation. Plane-strain compression loading was employed in the FE models to simulate cold rolling with reductions from ~80% to ~94%. Stringer analyses with the consideration of particle fracture were then performed with the simulated cold rolling results. The results of void evolution analyses show that microstructures with elliptical particles incorporate a much larger (almost double) void volume fraction than those with circular particles, indicating that the elliptical particles are fractured more easily than the circular ones. The results from the fracture mode analyses show that, under the adopted simple compression loading assumption, almost all the particles (i.e., >99%) were fractured by tensile separation. The results of stringer analyses show that, during cold rolling, the stringer volume fractions increase substantially due to the particle fracture, especially for the microstructures with the elliptical particles, and that the stringer volume fractions from stringers comprising many particles tend to increase faster. The maximum stringer lengths for the microstructures with circular particles tend to remain constant or decrease during cold rolling, whereas those for elliptical particles tend to slightly increase after a slight decrease. The number of particles at the surface increases very rapidly due to particle fracture during cold rolling.

36 MATERIALS SCIENCE↗

Wind-tunnel investigation at supersonic speeds of a canard-controlled missile with fixed and free-rolling tail fins

A wind tunnel investigation was made at free stream Mach numbers from 1.70 to 2.86 to determine the effects of fixed and free rolling tail fin afterbodies on the static longitudinal and lateral aerodynamic characteristics of a cruciform canard controlled missile model. The effect of small canard roll and yaw control deflections was also examined. The results indicate that the fixed and free rolling tail configurations have about the same lift curve slope and longitudinal stability level at low angles of attack. For the free rolling tail configuration, the canards provide conventional roll control with no roll control reversal at low angles of attack. The free rolling tail configuration reduced induced roll due to model roll angle and canard yaw control.

Blair, A. B., Jr.↗

Computer-aided analysis and design of the shape rolling process for producing turbine engine airfoils

Mild steel (AISI 1018) was selected as model cold rolling material and Ti-6A1-4V and Inconel 718 were selected as typical hot rolling and cold rolling alloys, respectively. The flow stress and workability of these alloys were characterized and friction factor at the roll/workpiece interface was determined at their respective working conditions by conducting ring tests. Computer-aided mathematical models for predicting metal flow and stresses, and for simulating the shape rolling process were developed. These models utilized the upper bound and the slab methods of analysis, and were capable of predicting the lateral spread, roll separating force, roll torque, and local stresses, strains and strain rates. This computer-aided design system was also capable of simulating the actual rolling process, and thereby designing the roll pass schedule in rolling of an airfoil or a similar shape.

Lahoti, G. D.↗

Nucleation and growth of rolling contact failure of 440C bearing steel

A 'two-body' elasto-plastic finite element model of 2-dimensional rolling and rolling-plus-sliding was developed to treat the effect of surface irregularities. The model consists of a smooth cylinder in contact with a semi-infinite half-space that is either smooth or fitted with one of 0.4 microns deep or 7 microns deep groove, or a 0.4 microns high ridge-like asperity. The model incorporates elastic-linear-kinematic hardening-plastic (ELKP) and non-linear-kinematic hardening-plastic (NLKP) material constitutive relations appropriate for hardened bearing steel and the 440C grade. The calculated contact pressure distribution is Hertzian for smooth body contact, and it displays intense, stationary, pressure spikes superposed on the Hertzian pressure for contact with the grooved and ridged surface. The results obtained for the 0.4 microns deep groove compare well with those reported by Elsharkawy and Hamrock for an EHD lubricated contact. The effect of translating the counterface on the half space as opposed to indenting the half space with the counter face with no translation is studied. The stress and strain values near the surface are found to be similar for the two cases, whereas they are significantly different in the subsurface. It is seen that when tiny shoulders are introduced at the edge of the groove in the finite element model, the incremental plasticity and residual stresses are significantly higher in the vicinity of the right shoulder (rolling direction is from left to right) than at the left shoulder. This may explain the experimental observation that the spall nucleation occurs at the exit end of the artificially planted indents. Pure rolling calculations are compared with rolling + sliding calculations. For a coefficient of friction, mu = 0.1, the effect of friction is found to be small. Efforts were made to identify the material constitutive relations which best describe the deformation characteristics of the bearing steels in the initial few cycles. Elastic-linear-kinematic hardening-plastic (ELKP) material constitutive relations produce less net plastic deformation in the initial stages for a given stress, than seen in experiments. A new set of constitutive relations: non-linear-kinematic hardening-plastic (NLKP) was used. This material model produces more plasticity than the ELKP model and shows promise for treating the net distortions in the early stages. Techniques for performing experimental measurements that can be compared with the finite element calculations were devised. The measurements are being performed on 9mm-diameter, 440C steel cylindrical rolling elements in contact with 12.5 mm-diameter, 52100 steel balls in a 3-ball-rod fatigue test machine operating at 3600 RPM. Artificial, 7 microns deep, indents were inserted on the running track of the cylindrical rolling elements and profilometer measurements of these indents made, before and after the rolling. These preliminary measurements show that the indents are substantially deformed plastically in the process of rolling. The deformations of the groove calculated with the finite element model are comparable to those measured experimentally.

Gupta, V.↗

Roll Utilization of an F-100A Airplane During Service Operational Flying

As a means of evaluating the roll utilization of a fighter airplane capable of supersonic speeds, an instrumented North American F-100A fighter airplane was flown by U.S. Air Force pilots at Nellis Air Force Base, NV, during 20 hours of service operational flying. Mach numbers up to 1.22 and altitudes up to 50,000 feet were realized in this investigation. Results of the study showed that except for high g barrel rolls performed as evasive maneuvers and rolls performed in acrobatic flying, rolling was utilized primarily as a means of changing heading. Acrobatic and air combat maneuvering produced the largest bank angles (1,200 deg), roll velocities (3.3 radians/sec), rolling accelerations (8 radians/sq sec) and sideslip angles (10.8 deg). Full aileron deflections were utilized on numerous occasions. Although high rolling velocities and accelerations also were experienced during several air-to-air gunnery missions, generally, air-to-air gunnery and air-to-ground gunnery and bombing required only two-thirds of maximum aileron deflection. The air-to-air gunnery and air combat maneuvers initiated from supersonic speeds utilized up to two-thirds aileron deflection and bank angles of less than 18 deg and resulted in rolling velocities and accelerations of 2 radians per second and 4.6 radians/sq sec, respectively. Rolling maneuvers were often initiated from high levels of normal acceleration, but from levels of negative normal acceleration only once.

Matranga, Gene J.↗

Texture Evolution in an Al-Cu-Mg Alloy During Hot Rolling

The texture evolution in the intermediate (the 1/4 thickness) layer of hot-rolled Al-Cu-Mg alloy sheets was investigated by the x-ray diffraction technique, electron backscattered diffraction analysis and transmission electron microscopy observation. The results showed that a texture transition from the shear texture {001}<110> to the β-fiber textures occurred as the rolling temperature increased to 420 °C. The shear strain caused by friction resulted in this strong shear texture formation at the low rolling temperature. As the rolling temperature increased, the plane strain substituting the shear strain dominated in the intermediate layer, giving rise to a significant increase in the β-fiber textures. Increasing the rolling temperature was found to preferentially activate the non-octahedral {112}<110> slip system, thereby benefiting the development of strong Brass. At the low rolling reduction of 74%, the textures with low intensity tended to converge on the α-fiber, containing Goss, Brass, P and L components. As the rolling reduction increased to 90%, the textures were strengthened and gradually flew toward the β-fiber, containing Brass, Copper and S components. The S and Copper bands were found to be the preferential sites for the development of recrystallizing Cube grains during hot rolling.

36 MATERIALS SCIENCE↗

Effect of cold rolling on microstructure and mechanical property of extruded Mg–4Sm alloy during aging

Microstructure and mechanical properties of the Mg–4Sm (wt.%) alloy, prepared via combined processes of extrusion, cold rolling and aging, have been investigated. The hot extruded alloy exhibits a weak rare earth magnesium alloy texture with < 11 − 21 >//ED, while the cold-rolled alloy shows a stronger basal texture with < 0001 >//ND. Many tensile twins and double twins are observed in grains after rolling. The cold-rolled alloy shows a weak age-hardening response compared with the extruded alloy, which is the result of more precipitation in the twin boundary during aging. The rolled alloy exhibits almost no precipitate free zone during aging compared with the extruded alloy. The higher proof stress of the rolled alloy in peak-aged condition is attributed to the presence of twin boundaries, stronger basal texture, higher dislocation density, and the suppression of precipitate free zone compared with the extruded alloy. - Highlights: • No precipitate free zone appears in cold-rolled alloy after aging. • Segregation and precipitates are observed in twin boundaries and grain boundaries. • Cold-rolled alloy shows a weak age-hardening response.

36 MATERIALS SCIENCE↗

Effect of cold rolling on the microstructural evolution of new β-typed Ti–6Mo–6V–5Cr–3Sn–2.5Zr alloys

A Ti–6Mo–6V–5Cr–3Sn–2.5Zr (wt.%) alloy was designed as a new metastable β-Ti alloy. The effect that cold rolling had on the microstructural evolution of the material was investigated via optical microscopy (OM), X-ray diffraction (XRD), electron back-scattered diffraction (EBSD) and transmission electron microscopy (TEM) measurements. A single β phase formed in the alloy after solution treatment at 780 °C for 30 min followed by water quenching. The solution-treated alloy was cold rolled with thickness reductions of 10%, 30%, 50% and 70%, and the hardness values increased as the thickness of the specimen decreased. The textures of the cold rolled specimen were characterized according to the 〈110〉 partial parallel to the rolling direction as the rolling reduction increased. The crystallographic orientation showed principal α-fiber textures for (111)〈110〉 and (112)〈110〉. The cold deformation led to the appearance of martensite α″ phases, particularly stress-induced martensite (SIM) α″ phases. - Highlights: • Effect of cold rolling on new β-typed Ti-6Mo-6V-5Cr-3Sn-2.5Zr alloy was studied. • A single β phase was obtained after solution treatment at 780 °C for 30 min. • α-Fiber textures became dominated with the increase in cold rolling reduction. • A stress-induced α″ martensite was caused by cold rolling.

36 MATERIALS SCIENCE↗

Influence of differential speed rolling ratio on the ridging behavior of ultra purified 17%Cr ferritic stainless steel

Highlights: • Differential rolling process improves ridging resistance of ferritic stainless steel. • Texture orientation inhomogeneity were attributed to non-uniform deformation. • Shear bands results in homogeneous deformation and recrystallization nucleation. • Uniform recrystallization grains and random orientation grains were obtained. - Abstract: The effect of the differential speed rolling on the ridging resistance and the crystallographic texture evolution of ultra purified 17%Cr ferritic stainless steel was investigated in order to select the optimal procedure for improving the surface quality. In the present study, the three different cold rolling processes were carried out: a conventional cold rolling and two different speed ratios asymmetric rolling. In the conventional cold rolling, the ridging of ferritic stainless steel was pronounced due to the band-like clusters of grains with similar crystallographic orientations. For differential speed rolling, ridging depth decreased and ridging was less pronounced when a higher different speed ratio was applied. The results show that severe ridging is attributed to the presence of band-like clusters of γ-fiber (<111>//ND) oriented grains. The shear bands introduced by differential speed rolling can enhance the nucleation for recrystallization both in grain interiors and grain boundaries, which can fragment the band-like clusters of similar orientation effectively, promoting the random grain orientation and improving surface quality.

36 MATERIALS SCIENCE↗

Finite element modelling of process-integrated powder coating by radial axial rolling of rings

The process-integrated powder coating by radial axial rolling of rings represents a new hybrid production technique applied in the manufacturing of large ring-shaped work pieces with functional layers. It is thought to break some limitations that come along with the hot isostatic pressing (HIP) which is used nowadays to apply the powdery layer material onto the rolled substrate ring. Within the new process the compaction of the layer material is integrated into the ring rolling and HIP becomes dispensable. Following this approach the rolling of such compound rings brings up some new challenges. The volume of a solid ring stays nearly constant during the rolling. This behaviour can be exploited to determine the infeed of the rollers needed to reach the desired ring shape. Since volume consistency cannot be guaranteed for the rolling of a compound ring the choice of appropriate infeed of the rollers is still an open question. This paper deals with the finite element (FE) simulation of this new process. First, the material model that is used to describe the compaction of the layer material is shortly reviewed. The main focus of the paper is then put on a parameterized FE ring rolling model that incorporates a control system in order to stabilize the process. Also the differences in the behaviour during the rolling stage between a compound and a solid ring will be discussed by means of simulation results.

36 MATERIALS SCIENCE↗

Some Effects of Roll Rate on the Longitudinal Stability Characteristics of a Cruciform Missile Configuration as Determined from Flight Test for a Mach Number Range of 1.1 to 1.8

A model of a cruciform missile configuration having a low-aspectratio wing equipped with flap-type controls was flight tested in order to determine stability and control characteristics while rolling at about 5 radians per second. Comparison is made with results from a similar model which rolled at a much lower rate. Results showed that, if the ratio of roll rate to natural circular frequency in pitch is not greater than about 0.3, the motion following a step disturbance in pitch essentially remains in a plane in space. The slope of normal-force coefficient against angle of attack C(sub N(sub A)) was the same as for the slowly rolling model at O deg control deflection but C(sub N(sub A)) was much higher for the faster rolling model at about 5 deg control deflection. The slope of pitching-moment coefficient against angle of attack & same for both models at 0 deg control deflection but was lower for the faster rolling model at about 5 deg control deflection. Damping data for the faster rolling model showed considerably more scatter than for the slowly rolling model.

Barber, H. T., Jr.↗

Rolling maneuver load alleviation using active controls

Rolling Maneuver Load Alleviation (RMLA) was demonstrated on the Active Flexible Wing (AFW) wind tunnel model in the LaRC Transonic Dynamics Tunnel. The design objective was to develop a systematic approach for developing active control laws to alleviate wing incremental loads during roll maneuvers. Using linear load models for the AFW wind-tunnel model which were based on experimental measurements, two RMLA control laws were developed based on a single-degree-of-freedom roll model. The RMLA control laws utilized actuation of outboard control surface pairs to counteract incremental loads generated during rolling maneuvers and roll performance. To evaluate the RMLA control laws, roll maneuvers were performed in the wind tunnel at dynamic pressures of 150, 200, and 250 psf and Mach numbers of .33, .38, and .44, respectively. Loads obtained during these maneuvers were compared to baseline maneuver loads. For both RMLA controllers, the incremental torsion moments were reduced by up to 60 percent at all dynamic pressures and performance times. Results for bending moment load reductions during roll maneuvers varied. In addition, in a multiple function test, RMLA and flutter suppression system control laws were operated simultaneously during roll maneuvers at dynamic pressures 11 percent above the open-loop flutter dynamic pressure.

Woods-Vedeler, Jessica A.↗

Rolling Maneuver Load Alleviation using active controls

Rolling Maneuver Load Alleviation (RMLA) has been demonstrated on the Active Flexible Wing (AFW) wind tunnel model in the NASA Langley Transonic Dynamics Tunnel. The design objective was to develop a systematic approach for developing active control laws to alleviate wing incremental loads during roll maneuvers. Using linear load models for the AFW wind-tunnel model which were based on experimental measurements, two RMLA control laws were developed based on a single-degree-of-freedom roll model. The RMLA control laws utilized actuation of outboard control surface pairs to counteract incremental loads generated during rolling maneuvers and actuation of the trailing edge inboard control surface pairs to maintain roll performance. To evaluate the RMLA control laws, roll maneuvers were performed in the wind tunnel at dynamic pressures of 150, 200, and 250 psf and Mach numbers of 0.33, .38 and .44, respectively. Loads obtained during these maneuvers were compared to baseline maneuver loads. For both RMLA controllers, the incremental torsion moments were reduced by up to 60 percent at all dynamic pressures and performance times. Results for bending moment load reductions during roll maneuvers varied. In addition, in a multiple function test, RMLA and flutter suppression system control laws were operated simultaneously during roll maneuvers at dynamic pressures 11 percent above the open-loop flutter dynamic pressure.

Woods-Vedeler, Jessica A.↗

Mixed convective/dynamic roll vortices and their effects on initial wind and temperature profiles

The onset and development of both dynamically and convectively forced boundary layer rolls are studied with linear and nonlinear analyses of a truncated spectral model of shallow Boussinesq flow. Emphasis is given here on the energetics of the dominant roll modes, on the magnitudes of the roll-induced modifications of the initial basic state wind and temperature profiles, and on the sensitivity of the linear stability results to the use of modified profiles as basic states. It is demonstrated that the roll circulations can produce substantial changes to the cross-roll component of the initial wind profile and that significant changes in orientation angle estimates can result from use of a roll-modified profile in the stability analysis. These results demonstrate that roll contributions must be removed from observed background wind profiles before using them to investigate the mechanisms underlying actual secondary flows in the boundary layer. The model is developed quite generally to accept arbitrary basic state wind profiles as dynamic forcing. An Ekman profile is chosen here merely to provide a means for easy comparison with other theoretical boundary layer studies; the ultimate application of the model is to study observed boundary layer profiles. Results of the analytic stability analysis are validated by comparing them with results from a larger linear model. For an appropriate Ekman depth, a complete set of transition curves is given in forcing parameter space for roll modes driven both thermally and dynamically. Preferred orientation angles, horizontal wavelengths and propagation frequencies, as well as energetics and wind profile modifications, are all shown to agree rather well with results from studies on Ekman layers as well as with studies on near-neutral and convective atmospheric boundary layers.

Haack, Tracy↗

Some Effects of Roll Rate on the Longitudinal Stability Characteristics of a Cruciform Missile Configuration as Determined from Flight Test for a Mach Number Range of 1.1. to 1.8

A model of a cruciform missile configuration having a low-aspect-ratio wing equipped with flap-type controls was flight tested in order to determine stability and control characteristics while rolling at about 5 radians per second. Comparison is made with results from a similar model which rolled at a much lower rate. Results showed that, if the ratio of roll rate to natural circular frequency in pitch is not greater than about 0.3, the motion following a step disturbance in pitch essentially remains in a plane in space. The slope of normal- force coefficient against angle of attack C(sub N(sub alpha)) was the same as for the slowly rolling model at 0 degrees control deflection but C(sub N(sub alpha)) was much higher for the faster rolling model at about 5 degrees control deflection. The slope of pitching-moment coefficient against angle of attack C(sub m(sub alpha)) as determined from the model period of oscillation was the same for both models at 0 degrees control deflection but was lower for the faster rolling model at about 5 degrees control deflection. Damping data for the faster rolling model showed considerably more scatter than for the slowly rolling model.

Lundstrom, Reginald R↗

Effects of False Tilt Cues on the Training of Manual Roll Control Skills

This paper describes a transfer-of-training study performed in the NASA Ames Vertica lMotion Simulator. The purpose of the study was to investigate the effect of false tilt cues on training and transfer of training of manual roll control skills. Of specific interest were the skills needed to control unstable roll dynamics of a mid-size transport aircraft close to the stall point. Nineteen general aviation pilots trained on a roll control task with one of three motion conditions: no motion, roll motion only, or reduced coordinated roll motion. All pilots transferred to full coordinated roll motion in the transfer session. A novel multimodal pilot model identification technique was successfully applied to characterize how pilots' use of visual and motion cues changed over the course of training and after transfer. Pilots who trained with uncoordinated roll motion had significantly higher performance during training and after transfer, even though they experienced the false tilt cues. Furthermore, pilot control behavior significantly changed during the two sessions, as indicated by increasing visual and motion gains, and decreasing lead time constants. Pilots training without motion showed higher learning rates after transfer to the full coordinated roll motion case.

simulators↗

Validation testing of the Canberra mobile Feed Roll Assay system - 15404

Japanese farmers grow various grasses as feed for cattle. These are rolled up and sealed for future use. Canberra has created a special truck to monitor these Feed Rolls, called 'Feed Roll Assay System [FRAS]'. On the bed of the truck is the shield containing a large NaI detector. The detector is 3x5x16'' in size, the same size as used in the Canberra FastScan Whole Body Counter. The detector is also LED-stabilized, to keep the gain constant under the wide range of temperature variations expected for this outdoor measurement instrument. The Canberra Osprey digital MCA is connected to the detector. The detector and the MCA are housed in a water proof box, which is surrounded on the bottom and all sides by a 15 cm thick steel shield. A portion of the shield at the top is open where the detector can view the Feed Rolls placed there. A single ethernet cable goes to a laptop PC which provides power to the MCA and detector, and also transmits the signal to the PC. The system was calibrated using MCNP for a variety of different densities, and Feed Roll sizes. The Japanese version of the Canberra Genie software is used to analyze the spectra and compute the Bq/kg concentration of the Feed Roll. The shielding is sufficient so that at a 5 uSv/hr background dose rate, no Cs-137 or Cs-134 peaks were detected in a 1 hour count. Measurements were performed in 0.2 uSv/hr dose rate, using uncontaminated Feed Rolls at various counting times. The MDA for Cs-137 was 11.9 Bq/kg at 30 seconds, 8.2 Bq/kg for 60 seconds, and 1.1 Bq/kg at 3600 seconds count time. The relative measurement uncertainty of the FRAS measurements was 9.4 to 13%, as compared to assays of samples extracted [30-45%] and in-situ Ge measurements [6.0 - 7.1%]. The FRAS measurement results have considerably better precision than measurements of samples extracted from the Feed Rolls, and are much faster than the in-situ Ge measurements and have just about the same uncertainty. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗