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At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Distributed Sapphire Fiber Bragg Gratings Based Thermal Profiling of Submerged Entry Nozzles

This research focuses on the application of sapphire fiber Bragg gratings (FBGs) for instrumentation in submerged entry nozzles (SEN) within the steelmaking industry. The SEN is pivotal for transferring molten steel from a tundish to a mold, while preventing the infiltration of oxygen and nitrogen from the surrounding environment. Maintaining optimal flow conditions in the mold is crucial for ensuring casting process stability and maintaining high quality steel. Sapphire FBG sensors have been instrumented in SENs to enable distributed thermal mapping for monitoring the health of the SEN. The optical sensor comprises three cascaded sapphire FBGs inscribed using femtosecond laser technology into a one-meter-long sapphire crystalline fiber. The sensor underwent characterization in a laboratory setting up to 1600°C and was tested for long-term stability over 40 hours under extreme environmental conditions. The coupling between silica and sapphire fibers was investigated and implemented during sensor packaging. Here, the sensor successfully captured the pre-heat sequence of the SEN in real-world steelmaking operations. Compared to conventional thermocouples, sapphire FBG sensors demonstrated exceptional efficiency and precision. They offer potential benefits such as increased productivity, reduced energy consumption, and minimized carbon footprint in the steel industry.

Sapphire Fiber Bragg Grating↗
DOE OSTI2018

Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process

We report carbon fiber reinforced composites have received growing attention because of their superior performance and high potential for lightweight systems. An economic method to manufacture the parts made of these composites is a sequence of forming followed by a compression molding. The first step in this sequence is called preforming that forms the prepreg, which is the fabric impregnated with the uncured resin, to the product geometry, while the molding process cures the resin. Slip between different prepreg layers is observed in the preforming step, and it is believed to have a non-negligible impact on the resulting geometry. This paper reports a method to characterize the interaction between different prepreg layers, which should be valuable for future predictive modeling and design optimization. An experimental device was built to evaluate the interactions with respect to various industrial production conditions. The experimental results were analyzed for an in-depth understanding about how temperature, relative sliding speed, and fiber orientation affect the tangential interaction between two prepreg layers. Moreover, a hydro-lubricant model was introduced to study the relative motion mechanism of this fabric-resin-fabric system, and the results agreed well with the experiment data. Lastly, the interaction factors obtained from this research will be implemented in a preforming process finite element simulation model.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Response of Graphite to Dynamic Loading and Hypervelocity Jet Impacts

The compressive strengths of three varieties of high purity graphite, PCEA, NBG-18, and NBG-25, as well as the depth of penetration of small-scale charges into these materials was experimentally determined. These grades are similar in density, ranging from 1.80 – 1.85 g/cc, and nominal apparent porosity, ranging from 18% to 20%, but provide a wide range in maximum grain or particle size from 10s to 1000s of µm. Two very different manufacturing methods are also represented; PCEA is extruded while NBG-18 and NBG-25 are iso-molded. The quasistatic and dynamic strengths of each grade were determined on a load frame and split-Hopkinson pressure bar, respectively. The depth of penetration (DOP) of two small-scale shaped charges, the Teledyne RP-1 and RP-4, was determined against graphite. The global response of the RP-4 impacts was markedly different as the PCEA samples remained intact while all the NBG-25 samples split into 2 or 3 pieces after the jet penetration had completed. However, for all tests, the trusted DOPs fell within 2 cm. Preliminary hydrocode modeling of the penetration events used existing models that were not designed for graphite. The results can be tuned to reasonably reproduce the DOP, but the wound channel geometry is not reproduced well. A model designed for graphite would need to represent graphite’s non-linear and energy dissipation characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Experimental Characterization Of The Interaction Between Carbon Fiber Composite Prepregs During The Preforming Process

Carbon fiber composites have received growing attention because of their high performance. One economic method to manufacturing the composite parts is the sequence of forming followed by the compression molding process. In this sequence, the preforming procedure forms the prepreg, which is the composite with the uncured resin, to the product geometry while the molding process cures the resin. Slip between different prepreg layers is observed in the preforming step and this paper reports a method to characterize the properties of the interaction between different prepreg layers, which is critical to predictive modeling and design optimization. An experimental setup was established to evaluate the interactions at various industrial production conditions. The experimental results were analyzed for an in-depth understanding about how the temperature, the relative sliding speed, and the fiber orientation affect the tangential interaction between two prepreg layers. The interaction factors measured from these experiments will be implemented in the computational preforming program.

Composite, Preforming, Material characterization, ↗
DOE OSTI2013

Damaged silicon contact layer removal using atomic layer etching for deep-nanoscale semiconductor devices

Silicon atomic layer etching (ALET) using Cl{sub 2} is applied to remove the damaged layer on a 30 nm contact silicon surface formed by high-energy reactive ions during high aspect ratio contact etching, and its effects on the damage removal characteristics are investigated. Compared to a conventional damage removal method, such as the low-power CF{sub 4} plasma treatment technique, ALET produces less secondary damage to the substrate and gives exact etch depth control and extremely high etch selectivity to the contact SiO{sub 2} insulating pattern mold. When ALET is applied after a conventional damage removal technique, the sheet resistance of the damaged contact silicon surface is improved to a level close to that of a clean silicon surface, while exact atomic-scale depth control is maintained without changes in the pattern mold profile.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Sensitivity and variability of Presage dosimeter formulations in sheet form with application to SBRT and SRS QA

Purpose: To measure sensitivity and stability of the Presage dosimeter in sheet form for various chemical concentrations over a range of clinical photon energies and examine its use for stereotactic body radiation therapy (SBRT) and stereotactic radiosurgery (SRS) QA. Methods: Presage polymer dosimeters were formulated to investigate and optimize their sensitivity and stability. The dosimeter is composed of clear polyurethane base, leucomalachite green (LMG) reporting dye, and bromoform radical initiator in 0.9–1.0 mm thick sheets. The chemicals are mixed together for 2 min, cast in an aluminum mold, and left to cure at 60 psi for a minimum of two days. Dosimeter response was characterized at energies Co-60, 6 MV, 10 MV flattening-filter free, 15 MV, 50 kVp (mean 19.2 keV), and Ir-192. The dosimeters were scanned by a Microtek Scanmaker i800 at 300 dpi, 2{sup 16} bit depth per color channel. Red component images were analyzed with ImageJ and RIT. SBRT QA was done with gamma analysis tolerances of 2% and 2 mm DTA. Results: The sensitivity of the Presage dosimeter increased with increasing concentration of bromoform. Addition of tin catalyst decreased curing time and had negligible effect on sensitivity. LMG concentration should be at least as high as the bromoform, with ideal concentration being 2% wt. Gamma Knife SRS QA measurements of relative output and profile widths were within 2% of manufacturer’s values validated at commissioning, except the 4 mm collimator relative output which was within 3%. The gamma pass rate of Presage with SBRT was 73.7%, compared to 93.1% for EBT2 Gafchromic film. Conclusions: The Presage dosimeter in sheet form was capable of detecting radiation over all tested photon energies and chemical concentrations. The best sensitivity and photostability of the dosimeter were achieved with 2.5% wt. LMG and 8.2% wt. bromoform. Scanner used should not emit any UV radiation as it will expose the dosimeter, as with the Epson 10000 XL scanner. Presage dosimeter in this form was sensitive enough for use in SRS and SBRT QA. The lower gamma pass rate for Presage compared to Gafchromic film can be attributed to the simple equipment used in the fabrication process, which limited the dosimeter’s sensitivity uniformity by agglomeration of air bubbles in the material, nonuniform concentration of chemicals throughout the material, and thickness variations. This demands improvements in mixing tools and molds.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Recovery of postconsumer mechanically recycled polymers

Mechanical recycling plays a key role in reducing landfill bound plastics that pollute our environment. This process converts plastic waste into marketable pellets by sorting, cleaning, grinding into flakes, compounding in the molten state, and ultimately pelletizing. A primary restriction for the widescale usage of mechanical recycling is the highly variable quality and mechanical properties of the plastic waste feedstock. Degradation can occur during the plastic life cycle with the consumer, during the mechanical processing itself, or during the complex sorting process required to produce the feedstock. This study explores how rheological characterization can mitigate the batch-to-batch variability and identify a potential application for each batch. Shear and extensional rheology of “application-specific” virgin high-density polyethylene (HDPE) and virgin polypropylene (PP) was used as the control for this categorization process. Recycled HDPE and PP from three different streams were then measured and compared to the results from the control study. Rheological measurements proved to be very effective at providing sufficient differentiation to categorize the recycled polymer as suitable for different applications such as injection molding, blow molding, or thermoforming. Finally, the usage of an additional step to sort the recycled polymers by their initial use application was found to achieve a remarkably consistent recovery of application-specific material properties. Furthermore, this secondary sorting could provide significant added value for mechanically recycled polymers.

Differential scanning calorimetry↗
DOE OSTI2019

Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications

Carbon fiber (CF)-reinforced thermoplastic composites have been widely used in different structural applications due to their superior thermal and mechanical properties. The big area additive manufacturing (BAAM) system, developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, has been used to manufacture several composite components, demonstration vehicles, molds, and dies. These components have been designed and fabricated using various CF-reinforced thermoplastics. In this study, the dynamic rheological and mechanical properties of a material commonly used in additive manufacturing, 20 wt% CF-acrylonitrile butadiene styrene (ABS), as well as three CF-reinforced high-temperature polymers, 25 wt% CF-polyphenylsulfone (PPSU), 35 wt% CF-polyethersulfone (PES), and 40 wt% CF-polyphenylene sulfide (PPS), used to print molds were investigated. The viscoelastic properties, namely storage modulus, loss modulus, tan delta, and complex viscosity, of these composites were studied, and the rheological behavior was related to the BAAM extrusion and bead formation process. The results showed 20 wt% CF-ABS and 40 wt% CF-PPS to display a more dominant elastic component at all frequencies tested while 25 wt% CF-PPSU and 35 wt% CF-PES have a more dominant viscous component. This viscoelastic behavior is then used to inform the deposition and bead formation process during extrusion on the BAAM system.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Numerical Simulation with Experimental Validation of the Draping Behavior of Woven Fabrics

Woven fabric composites are extensively used in molding complex geometrical shapes due to their high conformability compared to other fabrics. Preforming is an important step in the overall process. In this step, the two-dimensional fabric is draped to become the three-dimensional shape of the part prior to resin injection. During preforming, the orientation of the tows may change significantly compared to the initial orientations. Accurate prediction of the tow orientations after molding is important for evaluating the structural performance of the final part. This paper investigates the fiber angle changes for carbon fiber woven fabrics during draping over a truncated pyramid tool designed and fabricated at the General Motors Research Labs. This aspect of study is a subset of the broad study conducted under the purview of a Department of Energy project funded to GM in developing state of the art computational tools for integrated manufacturing and structural performance prediction of carbon fiber composites. Fabric bending, picture frame testing, and bias-extension evaluations were carried out to determine the material parameters for these fabrics. The PAM-FORM computer program was used to model the draping behavior of these fabrics. Following deformation, fiber angle changes at different locations on the truncated pyramid were measured experimentally. The predicted angles matched the experimental results well as measured along the centerline and at several different locations on the deformed fabric. Details of the test methods used as well as the numerical results with various simulation parameters will be provided.

42 ENGINEERING↗
DOE OSTI2016

Net Shape Fabricated Low Cost MHK Pass-Through the Hub Turbine Blades with Integrated Health Management Technology

The primary objective of this project is to develop a three-blade MHK rotor with low manufacturing and maintenance costs. The proposed program will design, fabricate and test a novel half-scale low cost, net shape fabricated single piece three-blade MHK rotor with integrated health management technology to demonstrate significant Capital Expenditures (CAPEX) and Operational Expenditures (OPEX) cost reductions due to the novel design and manufacturing process. The proposed project is divided into three major tasks: Task 1: Single Piece Three-blade Kinetic Hydropower System (KHPS) Rotor Full-Scale and Half-Scale Design; Task 2: Composite Manufacturing Trials and Half-Scale Prototype Rotor Fabrication; and Task 3: Material Characterization and Half-Scale Prototype Test and Evaluation. These three tasks include design and analysis of full-scale and half-scale three-blade rotor prototypes using computational fluid dynamics (CFD) and finite-element analysis (FEA), demonstration of a novel half-scale net shape fabrication process, determination of a fatigue threshold composite strain allowable, three-blade rotor mold design, manufacture of half-scale rotor clam shell mold, three-blade rotor test fixture design and fabrication, development of final manufacturing and test plans, manufacture of the half-scale net shape composite single blade and three-blade prototypes, and test and evaluation of the half-scale rotor.

16 TIDAL AND WAVE POWER↗
DOE OSTI2011

Evaluation of the residue from microset on various metal surfaces.

Fast-curing impression materials are sometimes used to cast negative-mold replications of physical defects on material surfaces. The negative-mold impressions can then be used for further measurements to record the nature of the defect. These impression materials have been designed to cure quickly, and with very low adhesion, so that they can be easily removed from the surface leaving little residual contamination. Unfortunately, some contaminant is retained by the substrate material. This investigation seeks to identify the composition and quantity of the remaining material upon removal of Microset Synthetic Rubber Replicating Compound from several material surfaces. Coe-Flex was used as a relative comparison to Microset. On fifteen different substrate materials the Microset leaves no visible trace of contaminant, however, X-ray photoelectron spectroscopy shows evidence of a thin silicone-based contaminant film of approximately 2 nm thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2011

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.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2011

PERMEABILITY TESTING OF SIMULATED SALTSTONE CORE AND VAULT 4 CELL E SALTSTONE

The Engineering Process Development Group (EPD) of the Savannah River National Laboratory (SRNL) prepared simulated saltstone core samples to evaluate the effect of sample collection by coring on the permeability of saltstone. The Environmental Restoration Technology Section (ERTS) of the SRNL was given the task of measuring the permeability of cores of simulated saltstone. Saltstone samples collected from Vault 4 Cell E using both dry and wet coring methods were also submitted for permeability analysis. The cores from Vault 4 Cell E were in multiple pieces when they were recovered (Smith, 2008 Cheng et.al, 2009). Permeability testing was only performed on the portions of the core sample that were intact, had no visible fractures or cracks, and met the specifications for 'undisturbed specimens' identified in Method ASTM D5084-03 Standard Test Methods for Measurement of Hydraulic Conductivity of Saturated Porous Materials Using a Flexible Wall Permeameter that was used for the testing. Permeability values for cores of simulated saltstone compared with values from permeability tests conducted on molded saltstone samples by an independent laboratory using the same method. All hydraulic conductivity results for Vault 4 samples exceeded results for both molded and cored saltstone simulant samples. The average hydraulic conductivity result for Vault 4 Cell E samples of 3.9 x 10{sup -7} cm/sec is approximately two orders of magnitude greater than that of the simulated saltstone with an average of 4.1 x 10{sup -9} cm/sec. Numerical flow and transport simulations of moisture movement through saltstone performed for the performance assessment of the Saltstone Disposal Facility (SDF) used 2.0 x 10{sup -9} cm/sec for the hydraulic conductivity of saltstone (Flach et al, 2009). The results for simulated versus actual saltstone were further compared using non-parametric statistics. The results from non-parametric statistical analysis of results indicate that there is at least a 98% probability that the hydraulic conductivity of saltstone samples collected from Vault 4 Cell E saltstone is greater than that of the baseline simulant mix.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2011

Status of Initial Assessment of Physical and Mechanical Properties of Graphite Grades for NGNP Appkications

Current candidate graphite grades for the core structures of NGNP include grades NBG-17, NBG-18, PCEA and IG-430. Both NBG-17 and NBG-18 are manufactured using pitch coke, and are vibrationally molded. These medium grain products are produced by SGL Carbon SAS (France). Tayo Tanso (Japan) produces IG-430 which is a petroleum coke, isostatically molded, nuclear grade graphite. And PCEA is a medium grain, extruded graphite produced by UCAR Carbon Co. (USA) from petroleum coke. An experimental program has been initiated to develop physical and mechanical properties data for these current candidate graphites. The results will be judged against the requirements for nuclear grade graphites set forth in ASTM standard D 7219-05 "Standard Specification for Isotropic and Near-isotropic Nuclear Graphites". Physical properties data including thermal conductivity and coefficient of thermal expansion, and mechanical properties data including tensile, compressive and flexural strengths will be obtained using the established test methods covered in D-7219 and ASTM C 781-02 "Standard Practice for Testing Graphite and Boronated Graphite Components for High-Temperature Gas-Cooled Nuclear Reactors". Various factors known to effect the properties of graphites will be investigated. These include specimen size, spatial location within a graphite billet, specimen orientation (ag and wg) within a billet, and billet-to-billet variations. The current status of the materials characterization program is reported herein. To date billets of the four graphite grades have been procured, and detailed cut up plans for obtaining the various specimens have been prepared. Particular attention has been given to the traceability of each specimen to its spatial location and orientation within a billet.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2011

EXAMINATION OF SHIPPING PACKAGES 9975-02274 AND 9975-04769

Shipping packages 9975-02274 and 9975-04769 were examined in K-Area following the identification of a non-conforming condition; the axial gap between the drum flange and upper fiberboard assembly exceeded the maximum allowed value of 1 inch. The fiberboard in package 9975-02274 had slightly elevated moisture content, up to 19% wood moisture equivalent (WME). Other compliant packages have displayed similar moisture levels locally, but not as consistently throughout the entire fiberboard assembly. Evidence of mold was observed on the lower assembly, although it appeared relatively dormant. Relatively little compaction or physical degradation was observed in this package. Due to the mold, it is recommended that the fiberboard in this package not be re-used. The fiberboard in package 9975-04769 was relatively dry (7-10% WME) and showed no sign of compaction or physical degradation. Variations in the axial gap that have been measured on this package result from variations in the height of the upper and lower fiberboard assemblies, and their relative orientation to each other. The fiberboard in this package is physically sound and considered fit for continued use.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2012

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.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Compound Refractive Lenses for Thermal Neutron Applications

This project designed and built compound refractive lenses (CRLs) that are able to focus, collimate and image using thermal neutrons. Neutrons are difficult to manipulate compared to visible light or even x rays; however, CRLs can provide a powerful tool for focusing, collimating and imaging neutrons. Previous neutron CRLs were limited to long focal lengths, small fields of view and poor resolution due to the materials available and manufacturing techniques. By demonstrating a fabrication method that can produce accurate, small features, we have already dramatically improved the focal length of thermal neutron CRLs, and the manufacture of Fresnel lens CRLs that greatly increases the collection area, and thus efficiency, of neutron CRLs. Unlike a single lens, a compound lens is a row of N lenslets that combine to produce an N-fold increase in the refraction of neutrons. While CRLs can be made from a variety of materials, we have chosen to mold Teflon lenses. Teflon has excellent neutron refraction, yet can be molded into nearly arbitrary shapes. We designed, fabricated and tested Teflon CRLs for neutrons. We demonstrated imaging at wavelengths as short as 1.26 Å with large fields of view and achieved resolution finer than 250 μm which is better than has been previously shown. We have also determined designs for Fresnel CRLs that will greatly improve performance.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2013

Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Clean Steel Casting Production

Inclusions in steel castings can cause rework, scrap, poor machining, and reduced casting performance, which can obviously result in excess energy consumption. Significant progress in understanding inclusion source, formation and control has been made. Inclusions can be defined as non-metallic materials such as refractory, sand, slag, or coatings, embedded in a metallic matrix. This research project has focused on the mold filling aspects to examine the effects of pouring methods and gating designs on the steel casting cleanliness through water modeling, computer modeling, and melting/casting experiments. Early in the research project, comprehensive studies of bottom-pouring water modeling and low-alloy steel casting experiments were completed. The extent of air entrainment in bottom-poured large castings was demonstrated by water modeling. Current gating systems are designed to prevent air aspiration. However, air entrainment is equally harmful and no prevention measures are in current practice. In this study, new basin designs included a basin dam, submerged nozzle, and nozzle extension. The entrained air and inclusions from the gating system were significantly reduced using the new basin method. Near the end of the project, there has been close collaboration with Wescast Industries Inc., a company manufacturing automotive exhaust components. Both computer modeling using Magma software and melting/casting experiments on thin wall turbo-housing stainless steel castings were completed in this short period of time. Six gating designs were created, including the current gating on the pattern, non-pressurized, partially pressurized, naturally pressurized, naturally pressurized without filter, and radial choke gating without filter, for Magma modeling. The melt filling velocity and temperature were determined from the modeling. Based on the simulation results, three gating designs were chosen for further melting and casting experiments on the same casting pattern using the lip pouring method. It was observed again that gating designs greatly influenced the melt filling velocity and the number of inclusion defects. The radial choked gating showed improvements in casting cleanliness and yield over the other gatings, even though no mold filters were used in the gating system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗