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At least 127 records · Page 7

Nucleation, Growth, Annealing, and Coagulation of Refractory Oxides and Metals: Recent Experimental Progress and Applications to Astrophysical Systems

Starting with cooling, refractory vapors diluted in significant quantities of H and He there are four processes that most natural systems will undergo: nucleation, growth, annealing, and coagulation. Nucleation is the processes by which the first stable refractory nuclei form in the vapor. These are the seeds onto which the remaining vapors will condense during the growth stage. Solids of any composition will try to arrange themselves into the least energetic configuration, provided that there is sufficient energy available to support such processes as diffusion and the breaking of chemical bonds. There is a significant activation energy associated with the annealing process in refractory solids due to the relatively high energy of the chemical bonds in solids. The grains formed in most cosmochemical systems are extremely small and often tightly coupled to the gas. Because of their small physical cross sections coagulation may be a very slow process unless there is another driving force involved in addition to normal Brownian motion. In what follows we will briefly cover each of these four stages for refractory oxide and metal grains, although in inverse order.

Nuth, J. A.↗

Performance Assessment of Refractory Concrete Used on the Space Shuttle's Launch Pad

The John F. Kennedy Space Center (KSC) maintains several facilities for launching space vehicles. During recent launches it has been observed that the refractory concrete materials that protect the steel-framed flame duct are breaking away from this base structure and are being projected at high velocities. There is significant concern that these projected pieces can strike the launch complex or space vehicle during the launch, jeopardizing the safety of the mission. A qualification program is in place to evaluate the performance of different refractory concretes and data from these tests have been used to assess the performance of the refractory concretes. However, there is significant variation in the test results, possibly making the existing qualification test program unreliable. This paper will evaluate data from past qualification tests, identify potential key performance indicators for the launch complex, and will recommend a new qualification test program that can be used to better qualify refractory concrete.

Trejo, David↗

Properties of Refractory Concrete in Tension and Compression

Refractory concrete on the LC-39A Flame Deflector has been damaged during multiple Space Shuttle launches (e.g. STS-124, STS-126, STS-119, and STS-125, STS-127). These events have prompted a better understanding of the system via an analytical model of the Flame Deflector assembly to include the Fondu Fyre refractory concrete. This model requires test data inputs of the refractory concrete's mechanical properties, which include stress versus strain curves in tension and compression, modulus of elasticity, and Poisson's ratio. Sections of Fondu Fyre refractory concrete removed from the LC-39A Flame Deflector were provided for this testing.

Sampson, Jeffrey↗

Refractory Materials for Flame Deflector Protection System Corrosion Control: Flame Deflector Protection System Life Cycle Cost Analysis Report

A 20-year life cycle cost analysis was performed to compare the operational life cycle cost, processing/turnaround timelines, and operations manpower inspection/repair/refurbishment requirements for corrosion protection of the Kennedy Space Center launch pad flame deflector associated with the existing cast-in-place materials and a newer advanced refractory ceramic material. The analysis compared the estimated costs of(1) continuing to use of the current refractory material without any changes; (2) completely reconstructing the flame trench using the current refractory material; and (3) completely reconstructing the flame trench with a new high-performance refractory material. Cost estimates were based on an analysis of the amount of damage that occurs after each launch and an estimate of the average repair cost. Alternative 3 was found to save $32M compared to alternative 1 and $17M compared to alternative 2 over a 20-year life cycle.

Calle, Luz Marina↗

ADDITIVE MANUFACTURING OF REFRACTORY ALLOYS

Refractory alloys are known for their high temperature capabilities and are intended for use at ultra-high temperatures above even 1200°C, which exceeds the capabilities of conventional superalloys. Additive manufacturing (AM) is an attractive alternative processing route because refractory alloys are difficult to fabricate through traditional methods; AM can form a near net-shape part with a tailored microstructure. This work seeks to evaluate the solidification behavior of refractory alloys under AM conditions and establish corresponding solidification models. Two binary alloys, Mo30Nb and Nb7.5Ta, as well as the commercial Nb alloy, C103, and one refractory high entropy alloy (RHEA), MoNbTaTi, were subjected to single track melts in a laser powder bed fusion (LPBF) machine. Each melt track was evaluated in the scanning electron microscope (SEM), which determined that some AM conditions used led to non-ideal behavior. Electron backscatter diffraction (EBSD) revealed that the Nb7.5Ta, C103, and MoNbTaTi all exhibited new grain nucleation to various extents while the Mo30Nb exhibited primarily epitaxial growth. This was found to be inconsistent with solidification models that were developed for each alloy and each set of AM conditions to predict the columnar to equiaxed transition behavior (CET) of the experimental microstructures. This disparity was largely attributed to the input parameters for the solidification model, which were developed using Thermo-Calc and SYSWELD. These input parameters include the alloy specific Gibbs-Thomson coefficient and thermophysical properties, the solute specific liquidus slopes and partitioning coefficients, as well as the process specific thermal gradients. Each input parameter was evaluated to determine the likely changes required for the modeled values to generate solidification models that better correspond to what was observed experimentally.

Miklas, Abigail↗

USE OF NOVEL REFRACTORY DESIGN AND INSTALLATION TECHNIQUES FOR IMPROVED ENERGY EFFICIENCY IN IRON AND STEEL AND OTHER ENERGY INTENSIVE INDUSTRIES

This work describes a US Department of Energy funded program which unites key players to develop and deploy new technologies aimed at increasing energy efficiencies while reducing their overall energy and environmental footprint. The research brings together a vertically integrated collaborative team consisting of the end user (US Steel), material producers/suppliers (Allied Mineral Products and Reno Refractories), raw material suppliers (American Metallurgical Services, Minerals Manufacturing), and research organizations (Oak Ridge National Laboratory, National Energy Technology Laboratory and University of Alabama-Birmingham) with the objective of designing and producing new refractory materials. Design and production criteria are based on novel aggregates, improved particle packing, and engineered surface textures. In addition, the recycling and use of spent refractory materials has been investigated resulting in development of a novel installation technique that utilizes additive manufacturing technology and existing refractory shotcrete technology. The combination of these new technologies will improve the energy, environmental, and economic efficiencies of the steel industry while reducing the environmental footprint. The developed technology is potentially applicable to additional energy intensive industries including cement, glass, pulp and paper, and non-ferrous metals processing.

Hemrick, James↗

Microstructure and Chemical Composition of Al2O3-, Cr2O3- and MgO-rich Refractories Exposed to Plastic Ashes

Plastics are widely integrated with today’s lifestyle due to their low cost, durability, lightweight, water resistance, and flexibility. However, tremendous plastic waste cause severe threats to the environment. Thus, sustainable recycling of plastic waste is critical, where plastic waste gasification technology with carbon management becomes one of the most effective recycling methods. We simulate the gasification process by exposing the Al2O3-, Cr2O3- and MgO-rich refractories to synthetic plastic ashes at 1500 ℃ for 50 h. A comprehensive study on the microstructure and chemical composition change before/after exposure is conducted using scanning electron microscopy. Meanwhile, the differences among these three refractories after exposure are revealed for quantifying the performance in plastic ashes. Discussion of the results will establish an understanding of the influence of plastic ashes on the microstructure, composition, and phase of different types of refractories, providing insights into designing new refractory materials for future recycling of plastic waste.

Fang, Xiaotian↗

Computational Fluid Dynamics Simulations of Glass Vitrification Refractory Coupon Tests

The Waste Treatment and Immobilization Plant (WTP) at the Hanford site is nearing the start of the Direct-Feed Low-Activity Waste (DFLAW) operations. DFLAW is destined to convert a pretreated low activity waste portion of the 56 million gallons of tank waste into a stable solid glass. In the subsequent decade completion of the high-level waste (HLW) facility is anticipated. Sustained operational missions of both LAW and HLW melter facilities are expected over multiple decades. In high-temperature glass melters, the refractory lining corrodes over time, which could potentially be an issue for longer term operations, this refractory corrosion is higher at the level of the glass-air interface due to surface tension driven flow. The glass viscosity, melt pool temperature, and glass chemical composition can impact the rate at which the refractory corrodes. This rate is important to quantify for the various waste glasses to be produced at the WTP since the integrity of the refractory should not be a limiting factor affecting the lifetime of the melter. To this end, a series of glasses representative of the first batches of waste glass produced by the WTP will be melted in small-scale crucibles with Monofrax® K-3 coupons inserted. The corrosion of the K-3 will be measured in the melt and at the meltline (or neckline). A model for the corrosion rate will be constructed and implemented into a previously developed framework for a computational fluid dynamics (CFD) model of the full-scale WTP. To assist with experimental design and validate the implementation of the model in the full-scale melter, CFD simulations of the small-scale crucible tests were performed. The bubbling that occurs in the small-scale crucible is initially validated here with a model that uses silicone oil at room temperature. The viscosity of the oil ranges from 1 to 100 Pa•s, which corresponds to operating glass pool temperatures near 1150 °C down to idling temperatures near 950 °C. The simulation results show good agreement with the bubble sizes that form during experiments. CFD modeling of the crucible setup was used to determine bubbling characteristics to match the range of near-wall velocities expected in the full-scale WTP. This study presents the initial CFD modeling results, corrosion testing plan, and some preliminary corrosion samples with an outline for the next steps for the development of the corrosion model.

Abboud, Alexander W. [Idaho National Lab]↗

Interface Analyses Between a Case-Hardened Ingot Casting Steel and Carbon-Containing and Carbon-Free Refractories

Corrosion tests of carbon-free and carbon-containing refractories were performed. The carbon-free crucibles corroded, whereas the carbon-containing crucibles were negligibly attacked. On them, inclusions were attached. This study investigates melt oxygen contents, interface properties, and steel compositions with their non-metallic inclusions in order to explore the inclusion formation and deposition mechanisms. The carbon-free crucibles were based on alumina, mullite, and zirconia- and titania-doped alumina (AZT). The carbon-containing (-C) ones were alumina-C and AZT-C. Furthermore, nanoscaled carbon and alumina additives (-n) were applied in an AZT-C-n material. In the crucibles, the case-hardened steel 17CrNiMo7-6 was remelted at 1580 °C. It was observed that the melt and steel oxygen contents were higher for the tests in the carbon-free crucibles. Into these crucibles, the deoxidizing alloying elements Mn and Si diffused. Reducing contents of deoxidizing elements resulted in higher steel oxygen levels and less inclusions, mainly of the inclusion group SiO 2 -core-MnS-shell (2.5 to 8 μm). These developed from smaller SiO 2 nuclei. The inclusion amount in the steel was highest after remelting in AZT-C-n for 30 minutes but decreased strongly with increasing remelting time (60 minutes) due to inclusions’ deposition on the refractory surface. The Ti from the AZT and the nanoadditives supported inclusion growth and deposition. Other inclusion groups were alumina and calcium aluminate inclusions. Their contents were high after remelting in carbon- or AZT-containing crucibles but generally decreased during remelting. On the AZT-C-n crucible, a dense layer formed from vitreous compositions including Al, Ca, Mg, Si, and Ti. To summarize, for reducing forming inclusion amounts, mullite is recommended as refractory material. For capturing formed inclusions, AZT-C-n showed a high potential.

36 MATERIALS SCIENCE↗

Refractory-based thermal energy storage for industrial process heat: one-dimensional modeling, control, and optimization

The variable and weather-dependent output of wind and solar power plants present a substantial challenge for planning and operating electricity-systems, particularly in the absence of cost-effective and dispatchable energy storage technologies. This study investigates a high-temperature, electrically heated, refractory-based thermal energy storage (RTES) system that stores electrical energy as sensible heat in dense ceramic bricks over the 950–1800 °C range. The stored heat can be discharged as a controlled hot-gas stream for industrial heating, fuel substitution in high-temperature processes, or electricity generation. The main novelty is a comprehensive modelling, control, mapping, and optimization framework that integrates one-dimensional transient gas–solid heat transfer, fan-assisted discharge, bypass-flow regulation, reheating logic, fan-power evaluation, insulation-loss assessment, and genetic-algorithm-based design optimization. The model uses feedback from outlet temperature and delivered power to regulate discharge, while a two-stage genetic algorithm optimizes brick-channel geometry, gas-flow operation, and multilayer insulation thicknesses. Storage capacities below 50 MWh and discharge powers of 5–30 MW are analyzed to evaluate hold time, thermal delivery, fan-power penalty, heat loss, state-of-charge evolution, and indicative capital cost. Results demonstrate that optimized and well-insulated refractory-based thermal energy storage units can provide stable, efficient, and repeatable heat delivery over multiple discharge cycles. The generated performance and cost maps support modular refractory thermal energy storage as a practical option for large-scale integration of wind and solar generation and for high-temperature industrial process heat.

25 ENERGY STORAGE↗

Transferable predictions of energetic and structural properties for refractory solid solution alloys across chemical compositions

We present a data-efficient approach to train graph neural networks (GNNs) on density functional theory (DFT) data for accurate and transferable predictions of energetic and structural properties of refractory solid solution alloys in the niobium-tantalum-vanadium (Nb-Ta-V) chemical space. We start by training the GNN model only on DFT data that describes refractory binary alloys niobium-tantalum (Nb-Ta), niobium-vanadium (Nb-V), and tantalum-vanadium (Ta-V) to predict formation enthalpy and root mean squared displacement. Once trained, the GNN predictions are tested on DFT data describing refractory ternary alloys Nb-Ta-V. While, unsurprisingly, direct transferability from binary to ternary is not sufficiently accurate, augmenting the training with only 1% of the available ternary data (uniformly distributed across the entire range of chemical compositions) improves significantly the quality of the GNN predictions. For comparison, we assess the transferability in the opposite direction by training GNN models on ternary Nb-Ta-V data and making predictions on binaries Nb-Ta, Nb-V, and Ta-V, which exhibits notably higher predictive errors. The proposed methodology, which favors transferability from lower-component to higher-component alloys, offers an efficient path towards avoiding the curse of dimensionality incurred when collecting DFT data for discovery and design of multi-component disordered alloys.

Density functional theory calculations↗

Reducing energy consumption and carbon emissions of magnesia refractory products: A life-cycle perspective

China is the largest producer of magnesia refractory materials and products in the world, resulting in significant energy consumption and carbon emissions. This paper analyzes measures to reduce both the energy consumption and carbon emissions in the production phase and use phase, providing a theoretical basis for a sustainable magnesia refractory industry. Results show that the total carbon emissions of carbon-containing magnesia bricks produced with fused magnesia are much higher than those of other products, and the total carbon emissions of both general magnesia brick and magnesia-carbon spray are lower than those of other products. Carbon emissions of magnesia products are mainly concentrated in the production process of magnesia. Manufacturers should select materials with lower environmental impacts and emphasize saving energy and reducing carbon emissions in the magnesia production process. Through scenario analysis we found that CO 2 capture is an effective measure to reduce carbon emissions compared with just improving energy consumption. However, a robust CO 2 market does not currently exist. Policy makers should plan on integrating CO 2 capture in the magnesia industry into a regional CO 2 capture and storage development planning in the long term. In particular, magnesia production is concentrated in a single geographical area which would and thus could take advantage of significant scale effects. Finally, in the use phase, extending the service lifetime reduces carbon emissions over the product lifetime, thus users should attempt to extend the service lifetime of a furnace as a whole. However, results show that it is not advisable to add a large number of repair refractories to extend the lifetime of existing furnaces.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Hard Magnetic, Low Neodymium Nd-Fe-B Melt-Spun Alloys Containing Refractory Metals

The effect of selected refractory metals addition on the structure and magnetic properties was studied for the nanocomposite Nd{sub 9}Fe{sub 77-x}B{sub 14}M{sub x}(M = Ti, Mo, Nb, Mn), Nd{sub 8}Fe{sub 78-x}B{sub 14}M{sub x}(M = Ti, Mo, Nb, Mn) and Nd{sub 7}Fe{sub 79-x}B{sub 14}Ti{sub x} systems. It was found that the addition of 2 and 4 at % of refractory metals leads to a substantial increase of the coercivity and maximum energy product for each of the nanocomposite systems while maintaining the remanence unchanged. The highest properties were obtained for the alloys containing 4-5 at% of the refractory metals. The maximum energy product of 143 kJ/m{sup 3} was achieved for the Nd{sub 8}Fe{sub 74}B{sub 14}Ti{sub 4} alloy.

36 MATERIALS SCIENCE↗

Effect of small-scale biomass gasification at the state of refractory lining the fixed bed reactor

The article deals with the influence of biomass gasification on the condition of the refractory lining of a fixed bed reactor. The refractory lining of the gasifier is one part of the device, which significantly affects the operational reliability and durability. After removing the refractory lining of the gasifier from the experimental reactor, there was done an assessment how gasification of different kinds of biomass reflected on its condition in terms of the main factors affecting its life. Gasification of biomass is reflected on the lining, especially through sticking at the bottom of the reactor. Measures for prolonging the life of lining consist in the reduction of temperature in the reactor, in this case, in order to avoid ash fusion biomass which it is difficult for this type of gasifier.

09 BIOMASS FUELS↗

Corrosion Testing of Refractory in Contact with Molten Glasses Designed for Waste Vitrification – APPS1 Matrix Glasses (Revision 3)

Preface or Acknowledgements This document serves to convey the refractory loss measurement results from corrosion testing of Monofrax® K-3 refractory by molten glass to support the enhanced waste glass program being led by Pacific Northwest National Laboratory (PNNL). Any discussion or conclusions to be drawn from the data are not presented in this report. The refractory corrosion data is intended to be used in the development, validation, and implementation of enhanced property/composition models for waste glass vitrification at Hanford. Funding for this work by the U.S. Department of Energy, Hanford Field Office, Waste Treatment & Immobilization Plant Project through Department of Energy Work Authorization M0SRV00101 managed by Albert A. Kruger is gratefully acknowledged.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy

Additive friction stir deposition (AFSD) is a solid-state metal additive manufacturing technique, which utilizes frictional heating and plastic deformation to create large deposits and parts. Much like its cousin processes, friction stir welding and friction stir processing, AFSD has seen the most compatibility and use with lower-temperature metals, such as aluminum; however, there is growing interest in higher-temperature materials, such as titanium and steel alloys. In this work, we explore the deposition of an ultrahigh-temperature refractory material, specifically, a tantalum–tungsten (TaW) alloy. The solid-state nature of AFSD means refractory process temperatures are significantly lower than those for melt-based additive manufacturing techniques; however, they still pose difficult challenges, especially in regards to AFSD tooling. In this study, we perform initial deposition trials of TaW using twin-rod-style AFSD with a high-temperature tungsten–rhenium-based tool. Many challenges arise because of the high temperatures of the process and high mechanical demand on AFSD machine hardware to process the strong refractory alloy. Despite these challenges, successful deposits of the material were produced and characterized. Mechanical testing of the deposited material shows improved yield strength over that of the annealed reference material, and this strengthening is mostly attributed to the refined recrystallized microstructure typical of AFSD. These findings highlight the opportunities and challenges associated with ultrahigh-temperature AFSD, as well as provide some of the first published insights into twin-rod-style AFSD process behaviors.

36 MATERIALS SCIENCE↗

An Open-Source Numerical Model for Mitigating Refractory Alloy Hot Cracking Susceptibility

Refractory alloys are susceptible to solidification cracking during welding and 3D printing. Composition control is an effective method of controlling solidification cracking. This work evaluates the effect of compositional variation in refractory metal systems on a computed solidification cracking susceptibility. A numerical model has been developed using Python code and open-source CALPHAD software to calculate Kou’s crack susceptibility index. The model is validated against past weldability studies performed on several refractory alloy systems. The approach is extended towards the development of new alloys with improved 3D printability and weldability and is shown to have utility in defining compositional limits for existing alloys and feedstocks. Furthermore, the model will aid in determining process controls for powder reuse and recycling.

pycalphad↗

Compositional inhomogeneity and its effect on the hardness of nanostructured refractory high-entropy alloys

The pronounced compositional inhomogeneity observed in refractory high-entropy alloys (HEAs), as opposed to non-refractory HEAs, has an important influence on their mechanical properties, thereby posing a significant challenge for the development of high-performance refractory HEAs. In this work, by combining transmission electron microscopy imaging, chemical analysis, and nano-hardness tests, we investigate the compositional inhomogeneities in a series of sintered nanostructured HEAs and elucidate their influence on the material's hardness. Further, we reveal that the compositional inhomogeneity of the sintered nanostructured HEAs is temperature- and component- dependent. By correlating the hardness of nanostructured HEAs to the evolving compositional inhomogeneity, our work demonstrates that the compositional inhomogeneity in nanostructured HEAs can be tuned by sintering temperature or alloying towards optimized microstructure and hardness.

77 NANOSCIENCE AND NANOTECHNOLOGY↗