SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
The Experimental Fuels Facility (EFF) Casting System, which is configured for gravity casting into a permanent mold, was installed to cast billets made up of uranium, uranium alloys, copper and copper alloys, as well as other geometries in support of the TerraPower project. This document describes casting development using.
This report presents an overview of LANL casting procedure and characterization of recent DU U-10 Mo castings and characterizes recent LEU U-10Mo casting from Y-12.
An iron-rich high entropy alloy Al 0.65 CoCrFe 2 Ni comprising of both FCC and BCC phases was designed and fabricated using induction melting at a large industrial scale and suction casting at a small lab scale. Spinodally decomposed interdendritic regions were uniformly distributed in the industrially melted alloy, and a finer dendritic structure with smaller sized spinodal structures was observed in the alloy suction cast at lab scale. The suction cast alloy fabricated at the lab scale exhibited significantly higher compressive yield strength compared to the industrially cast alloy. The relative strengthening contributions in the alloys due to solid solution, grain boundary, dislocation interactions and interphase boundary were analyzed. Dislocation hardening was the major contributor responsible for the higher strength of the SC alloy. The deformation behavior in the alloys was examined with the help of orientation image mapping. Finally, intense slip band formation at large strains in the industrially melted alloy indicates that cold working can be an effective technique to enhance the strength of the dual-phase high entropy alloy processed at a large scale.
Highlights: • The surface layer hardened much faster than the central region during age. • More quantity of finer precipitates was found in the surface layer during age. • The surface layer had a lower activation energy of precipitation. • Si promoted the precipitation via inducing dislocations in matrix. - Abstract: Microstructure and hardness evolution of a vacuum-assistant die-cast A380 alloy during heat treatment were investigated. Both surface layer and central region of the casting component were analyzed in die-cast state, solutionized state and artificial age state. During the artificial age, the surface layer hardened more significantly than the central region due to faster precipitation and more refined hardening phases in the surface layer. Detailed analysis on the macro-segregation, microstructure morphology and grain size revealed that the different aging behaviors exhibiting in the surface and the central region were mainly attributed to a combining effect of the enrichment of Si and Cu at the surface layer, the fully-divorced morphology of eutectic in die-cast microstructure, and the presence of the externally solidified crystals at the central region. The presence of the Si particles, which exhibited quite different thermal expansion properties, changed the density and the distribution of the dislocations in the α-Al matrix, and consequently changed the precipitation of the hardening phases.
A process for slip casting ceramic articles that does not employ parting agents and affords the casting of complete, detailed, precision articles that do not possess parting lines is presented. This process is especially useful for high temperature superconductors and water-sensitive ceramics. A wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip, created by dispersing a ceramic powder in an organic liquid, is poured therein. After a ceramic shell of desired thickness or a solid article has set up in the shell mold, excess ceramic slip is poured out. The shell mold is misted with water and peeled away from the ceramic article, after which the ceramic is fired to provide a complete, detailed, precision, high temperature superconductive ceramic article without parting lines. The casting technique may take place in the presence of a magnetic field to orient the ceramic powders during the casting process.
The high-temperature (600-900 °C) mechanical properties of EN 1.4509 stainless steel made by investment casting were studied by changing the Nb content based on this stainless steel composition standard. The results indicate that with an increase in tensile temperature, the high-temperature strength shows a downward trend and the high-temperature plasticity increases. The results also indicate that with an increase in Nb content, the high-temperature strength rises continually and the high-temperature plasticity decreases; for example, the tensile strengths at 900 °C of Steel A, Steel B and Steel C are 21, 25 and 31 MPa, respectively, and the yield strengths are 15, 20 and 22 MPa, respectively, and the elongations are 97.7, 85.3 and 73.7%, respectively. The high-temperature tensile strength of the investment casting EN 1.4509 stainless steel sample is closely related to the bulk (Ti, Nb) (C, N) and the Laves phase (Fe{sub 2}Nb) at the ferritic grain boundaries and in the ferritic grains. These are the main factors for improvement in the high-temperature strength of the tested steels; additionally, the coarse ferritic grains also play a certain role in improving the mechanical properties. The Nb content of the investment casting EN 1.4509 stainless steel can be reduced to 0.25 wt.%, and at this content, a combination of good high-temperature mechanical properties and higher room-temperature plasticity is obtained.
Not Available
Explore the source record for details and available documents.
The graphite nodule count and size distributions for boiling water reactor (BWR) and pressurized water reactor (PWR) inserts were investigated by taking samples at heights of 2160 and 1150 mm, respectively. In each cross section, two locations were taken into consideration for both the microstructural and solidification modeling. The numerical solidification modeling was performed in a two-dimensional model by considering the nucleation and growth in eutectic ductile cast iron. The microstructural results reveal that the nodule size and count distribution along the cross sections are different in each location for both inserts. Finer graphite nodules appear in the thinner sections and close to the mold walls. The coarser nodules are distributed mostly in the last solidified location. The simulation result indicates that the finer nodules are related to a higher cooling rate and a lower degree of microsegregation, whereas the coarser nodules are related to a lower cooling rate and a higher degree of microsegregation. The solidification time interval and the last solidifying locations in the BWR and PWR are also different.
Mechanical testing and microstructural characterization were performed on short-term thermally aged cast austenitic stainless steels (CASS) to understand the severity and mechanisms of thermal-aging degradation experienced during extended operation of light water reactor (LWR) coolant systems. Four CASS materials – CF3, CF3M, CF8, and CF8M – were thermally aged for 1500 hours at 290 °C, 330 °C, 360 °C, and 400 °C. All four alloys experienced insignificant change in strength and ductility properties but a significant reduction in absorbed impact energy. The primary microstructural and compositional changes during thermal aging were spinodal decomposition of the δ-ferrite into α/ α`, precipitation of G-phase in the δ-ferrite, segregation of solute to the austenite/ ferrite interphase boundary, and growth of M23C6 carbides on the austenite/ferrite interphase boundary. These changes were shown to be highly dependent on chemical composition, particularly the concentration of C and Mo, and aging temperature. A comprehensive model is being developed to correlate the microstructural evolution with mechanical behavior and simulation for predictive evaluations of LWR coolant system components.
The microstructure and mechanical properties in unaged and thermally aged (at 280 oC, 320 oC, 360 oC, and 400 oC to 4300 h) CF–3 and CF–8 cast duplex stainless steels (CDSS) are investigated. The unaged CF–8 steel has Cr-rich M23C6 carbides located at the δ–ferrite/γ– austenite heterophase interfaces that were not observed in the CF–3 steel and this corresponds to a difference in mechanical properties. Both unaged steels exhibit incipient spinodal decomposition into Fe-rich α–domains and Cr-rich α’–domains. During aging, spinodal decomposition progresses and the mean wavelength (MW) and mean amplitude (MA) of the compositional fluctuations increase as a function of aging temperature. Additionally, G–phase precipitates form between the spinodal decomposition domains in CF–3 at 360 oC and 400 oC and in CF–8 at 400 oC. The microstructural evolution is correlated to changes in mechanical properties.
The Casting and Solidification Technology (CAST) experiment will study the phenomena that occur during directional solidification of an alloy, e.g., constitutional supercooling, freckling, and dendrite coarsening. The reduced gravity environment of space will permit the individual phenomena to be examined with minimum complication from buoyancy driven flows.
Crystallisation of NH4Cl from aqueous solutions has been used to examine grain formation in a configuration similar to that existing in the curved mould of a continuous, steel casting machine. The observations show how falling equiaxed crystals accumulate at the lower (outer) columnar front earlier than at the upper (inner) front and, thus, lead to an asymmetric grain structure. The usefulness of the aqueous system as a realistic model for steel casting is discussed in terms of relative temperature profiles, materials properties, and observed columnar and eutectic growth rates.
A synchrotron technique, differential aperture X-ray microscopy (DAXM), has been applied to characterize the microstructure and analyze the local mesoscale residual elastic strain fields around graphite nodules embedded in ferrite matrix grains in ductile cast iron. Compressive residual elastic strains are measured with a maximum strain of ~6.5–8 × 10 –4 near the graphite nodules extending into the matrix about 20 μm, where the elastic strain is near zero. The experimental data are compared with a strain gradient calculated by a finite element model, and good accord has been found but with a significant overprediction of the maximum strain. This is discussed in terms of stress relaxation during cooling or during storage by plastic deformation of the nodule, the matrix or both. Furthermore, relaxation by plastic deformation of the ferrite is demonstrated by the formation of low energy dislocation cell structure also quantified by the DAXM technique.
Explore the source record for details and available documents.
The microstructural evolution of delta ferrite in a CF3 cast stainless steel irradiated to 3, 5, 10, 20, and 40 dpa with two dose rates was studied with atom probe tomography (APT) and transmission electron mi-croscopy. Spinodal decomposition and G-phase precipitates induced by neutron irradiation and thermal aging were quantified systematically. The neutron irradiation significantly enhances the spinodal decom-position in delta ferrite as both the spinodal wavelength (i.e. a characteristic repeat distance) and am-plitude (i.e. magnitude of elemental concentration fluctuation) increase after irradiation. The wavelength only varies slightly when the dose increases from 5 to 40 dpa, while the amplitude increases dramatically from 10 to 20 dpa and starts to saturate before 20 dpa. The dose rate and irradiation temperature also have a notable effect on the spinodal wavelength and amplitude. The study shows that higher dose rate promotes a larger wavelength at given irradiation doses. Regarding the G-phase precipitates, a slightly lower irradiation temperature would result in a smaller mean size of G-phase precipitates, while a lower irradiation dose rate would lead to a larger G-phase precipitates at a given temperature and dose. Over-all, the spinodal decomposition and G-phase precipitates in the delta ferrite continue to evolve with the increasing dose beyond 10 dpa. This study confirms that the formation of G-phase precipitates at the in-terdomain region between alpha and alpha-prime is facilitated by the Si and Mo atoms rejected from Fe rich alpha phase and the Ni and Mn atoms rejected from Cr rich alpha-prime phase. Neutron irradiation plays a dominant role in the ferrite instability, and the effect of prior thermal aging at 400 degrees C for 10,000 hours is negligible as the dose is 3 dpa and above.
Solid-state electrolytes are attractive for use in electrochemical devices because they remove the need for a flammable liquid electrolyte while contributing to the structural integrity of the device. We have recently developed a class of solid electrolytes, termed molecular ionic composites (MICs), composed of ionic liquids (ILs) and a rigid-rod polyelectrolyte, poly(2,2'-disulfonyl-4,4'-benzidine terephthalamide) (PBDT). MIC materials, originally obtained through an ion-exchange process between IL and PBDT aqueous solution, possess an unprecedented combination of high ionic conductivity, high thermal stability, low flammability and widely tunable tensile storage moduli. Here we present a facile solvent casting method for preparing MIC membranes. These membranes are uniform, flexible, and tough, with tunable composition and thickness (≥ 40 μm). Unlike the previous ion-exchange method, which only allowed incorporation of hydrophilic ILs, we can now incorporate hydrophobic ILs to prepare MIC membranes for, e.g. battery electrolytes. A sodium (Na) metal symmetric cell constructed with a PBDT-Pyr 14 TFSI membrane as the solid electrolyte shows long-term stable cycling (> 500 h.) at 60 °C. Furthermore, the ability to prepare MICs using both hydrophilic and hydrophobic ILs initiates a wider range of MIC materials and broadens the array of applications accessible by MIC membranes.
A high-refractory Ni-based superalloy prototype was melted on a research scale while simulating industry practices. Ingots were vacuum induction melted and subjected to a computationally optimized homogenization heat treatment prior to fabrication which consisted of forging and hot rolling. Failure of one of the ingots at the early stage of the forging process was attributed to the precipitation of the β-NiAl phase during melting which stabilized the eutectic constituent.