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At least 1,279 records · Page 71

Geometric Form of Gating System Elements and Its Influence on the Initial Filling Phase

Flow of cast steel through twenty-four variants of gating system was examined with the use of numerical modeling conducted in MAGMA. The main goal of the research was to determine the impact of the gating system elements’ geometric form on the kinetics in the initial filling phase, which is crucial in terms of castings quality. The evaluation was based on flow kinetics, maximal height, and the velocity of metal entering the mold. The variables included the geometric form of the sprue and the cross runner, as well as geometric form, length, and expansion of the ingate. Results allow to form valuable conclusions that can lead to improvement in the castings manufacturing technology. Results show that application of proper expansion of the ingate and suitable geometric form of the gating system can significantly reduce the velocity of metal entering the mold cavity, as well as eradicate the jetting, which positively impacts the soundness of the casting.

36 MATERIALS SCIENCE↗

A critical review of the history of fabricating monolithic U-Mo fuel plates

The fabrication of monolithic uranium-molybdenum alloy fuels, specifically those developed for high-performance research and test reactors, began in the early 2000s. The primary fuel form consists of uranium alloyed with 10-wt% molybdenum in a thin foil coated with zirconium and encapsulated in aluminum-6061 cladding. Over the years, the process has evolved with different types of casting, heat treatments, rolling schedules, and cladding applications. This review examines the history of these fabrication processes and their impact on microstructure and fuel-swelling performance. Even though various fabrication methods were used, we found little correlation between fabrication variation and fuel swelling. This insensitive relationship between fabrication variation and fuel swelling is primarily due to inhomogeneous microstructures that formed during casting and grain refinement that occurred during rolling. We conclude that the fabrication processes we examined produced similar microstructures, indicating that the fuel microstructure is somewhat insensitive to the fabrication parameters evaluated. However, the relatively small amount of historic data, such as those for grain sizes, limited this analysis. More recently fabricated materials, such as those from ongoing irradiation experiment, Mini-Plate-1 and Mini-Plate-2, were also excluded from this analysis and are intended to be reviewed separately. The findings, that fuel microstructure is somewhat insensitive to the fabrication parameters, do not imply that any fabrication method is acceptable, given the uncertainties in data and fuel-swelling observations. For example, only arc melting and vacuum induction melting casting processes were previously explored in the historic fabrication efforts. In conclusion, the findings should not be extrapolated to other casting processes.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Directly obtained τ-phase MnAl, a high performance magnetic material for permanent magnets

The metastable tetragonal τ-phase has been directly obtained from casting Mn{sub 0.54}Al{sub 0.46} and (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2} using the drop synthesis method. The as-casted samples were ball milled to decrease the particle size and relaxed at 500 °C for 1 h. The phase composition, crystallographic parameters, magnetic properties and microstructure were systematically studied. The results reveal that the τ-phase could be directly obtained from drop synthesis. The highest M{sub s} of 117 emu/g was achieved in the (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2} where the τ-phase was stabilized by doping with carbon. Carbon doping increased the c/a ratio of the τ-phase as it occupies specific interstitial positions (½, ½, 0) in the structure. Furthermore, ball milling increases the coercivity (H{sub c}) at the expense of a decrease in magnetic saturation (M{sub s}). The increase in coercivity is explained by a decrease of grain size in conjunction with domain wall pinning due to defects introduced during the ball milling process. - Graphical abstract: The tetragonal τ-phase has been directly obtained from casting Mn{sub 0.54}Al{sub 0.46} and (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2} using the drop synthesis method. The phase composition, crystallographic parameters, magnetic properties and microstructure were systematically studied. The highest M{sub s} of 117 emu/g was achieved for (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2} ball milling increases the coercivity (H{sub c}) at the expense of a decrease in magnetic saturation (M{sub s}). - Highlights: • The ferromagnetic τ-phase has been directly obtained from casting. • The highest M{sub s} of 117 emu/g was achieved for (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2}. • Ball milling increases the coercivity but decreases the magnetic saturation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Characterization of a 12-pdr wrought-iron cannonball from the Akko 1 shipwreck

The Akko 1 shipwreck, discovered in Akko harbor, Israel, is the remains of an eastern Mediterranean brig built at the beginning of the 19th century. Among other finds, eleven cannonballs were found in the shipwreck and three of them were retrieved. Two of the cannonballs, the 9- and 24-pdrs, have been studied previously. The present study of the 12-pdr cannonball included γ-rays radiographic testing, XRF analysis, density measurements, optical microscopy and SEM-EDS observation, OES analysis and microhardness tests. The investigation included characterization of the composition, microstructure and slag analysis. The results revealed a quite homogenous microstructure of α-ferrite phase, with glassy, wüstite and fayalite slags, as typical for a wrought-iron—annealed product, a more complicated and an earlier technology, compared to the 9- and 24-pdr that were made of cast-iron. Ferritic cannonballs are extremely rare, especially in the 19th century, when cannonballs were manufactured of cast iron by the sand casting process. The different manufacturing methods may indicate a different place of fabrication, and an apparently earlier production date for the 12-pdr, which might have even been used as ballast. - Highlights: • Three cannonballs were retrieved from the 19th century Akko 1 shipwreck. • The 12-pdr differs from the 9- and 24-pdr cannonballs previously studied. • The 12-pdr was made of high quality annealed wrought-iron, not of cast-iron. • The technology used indicates a date earlier than the middle of the 19th century. • Perhaps the 12-pdr belonged to another navy than the other two or used as ballast.

36 MATERIALS SCIENCE↗

X-ray tomography investigation of intensive sheared Al–SiC metal matrix composites

X-ray computed tomography (XCT) was used to characterise three dimensional internal structure of Al–SiC metal matrix composites. The alloy composite was prepared by casting method with the application of intensive shearing to uniformly disperse SiC particles in the matrix. Visualisation of SiC clusters as well as porosity distribution were evaluated and compared with non-shearing samples. Results showed that the average particle size as well as agglomerate size is smaller in sheared sample compared to conventional cast samples. Further, it was observed that the volume fraction of porosity was reduced by 50% compared to conventional casting, confirming that the intensive shearing helps in deagglomeration of particle clusters and decrease in porosity of Al–SiC metal matrix composites. - Highlights: • XCT was used to visualise 3D internal structure of Al-SiC MMC. • Al-SiC MMC was prepared by casting with the application of intensive shearing. • SiC particles and porosity distribution were evaluated. • Results show shearing deagglomerates particle clusters and reduces porosity in MMC.

36 MATERIALS SCIENCE↗

Microstructure evolution and mechanical properties of nano-SiCp/AZ91 composite processed by extrusion and equal channel angular pressing (ECAP)

Nano-SiCp/AZ91 magnesium matrix composite was fabricated by stir casting. The as-cast ingots were extruded at 350 °C, then processed by equal channel angular pressing (ECAP) at various temperatures (250 °C, 300 °C and 350 °C). Grains are significantly refined after the extrusion and the ECAP. A basal fibre texture was detected by neutron diffraction after the extrusion, which inclines about 45° to the extrusion direction (ED) after the ECAP. Nano-scaled SiC particles agglomerate in the as-cast composite. After the extrusion, the agglomeration tends to form continuous or discontinuous strips along the extrusion direction. By application of the ECAP, the agglomerated SiC particles are partly dispersed and the strips formed during the extrusion tend to be thinner and broken with the increasing pass number. The yield tensile strength (YTS) and the ultimate tensile strength (UTS) of the composite are dramatically increased after the extrusion. ECAP for one pass at various temperatures further increases the strength, however, the YTS decreases with the increasing ECAP temperature and the pass number. The Orowan equations predict the maximum YTS of the composite may be up to 400 MPa providing SiC particles are homogenously distributed in the matrix. - Highlights: •Nano-scaled SiC particles were successfully added into AZ91 by stirring casting. •Agglomeration of nano-particles were improved by extrusion and ECAP. •Yield strength of the composite is 328 MPa after one pass of ECAP. •Further ECAP process with optimized parameters may fully disperse nano-particles. •Yield strength is predicted to up to 400 MPa when particles are fully dispersed.

36 MATERIALS SCIENCE↗

Development of flexible, free-standing, thin films for additive manufacturing and localized energy generation

Film energetics are becoming increasingly popular because a variety of technologies are driving a need for localized energy generation in a stable, safe and flexible form. Aluminum (Al) and molybdenum trioxide (MoO{sub 3}) composites were mixed into a silicon binder and extruded using a blade casting technique to form flexible free-standing films ideal for localized energy generation. Since this material can be extruded onto a surface it is well suited to additive manufacturing applications. This study examines the influence of 0-35% by mass potassium perchlorate (KClO{sub 4}) additive on the combustion behavior of these energetic films. Without KClO{sub 4} the film exhibits thermal instabilities that produce unsteady energy propagation upon reaction. All films were cast at a thickness of 1 mm with constant volume percent solids to ensure consistent rheological properties. The films were ignited and flame propagation was measured. The results show that as the mass percent KClO{sub 4} increased, the flame speed increased and peaked at 0.43 cm/s and 30 wt% KClO{sub 4}. Thermochemical equilibrium simulations show that the heat of combustion increases with increasing KClO{sub 4} concentration up to a maximum at 20 wt% when the heat of combustion plateaus, indicating that the increased chemical energy liberated by the additional KClO{sub 4} promotes stable energy propagation. Differential scanning calorimeter and thermogravimetric analysis show that the silicone binder participates as a fuel and reacts with KClO{sub 4} adding energy to the reaction and promoting propagation.

36 MATERIALS SCIENCE↗

Viscosity Meaurement Technique for Metal Fuels

Metallic fuels have exceptional transient behavior, excellent thermal conductivity, and a more straightforward reprocessing path, which does not separate out pure plutonium from the process stream. Fabrication of fuel containing minor actinides and rare earth (RE) elements for irradiation tests, for instance, U-20Pu-3Am-2Np-1.0RE-15Zr samples at the Idaho National Laboratory, is generally done by melt casting in an inert atmosphere. For the design of a casting system and further scale up development, computational modeling of the casting process is needed to provide information on melt flow and solidification for process optimization. Therefore, there is a need for melt viscosity data, the most important melt property that controls the melt flow. The goal of the project was to develop a measurement technique that uses fully sealed melt sample with no Americium vapor loss to determine the viscosity of metallic melts and at temperatures relevant to the casting process. The specific objectives of the project were to: develop mathematical models to establish the principle of the measurement method, design and build a viscosity measurement prototype system based on the established principle, and calibrate the system and quantify the uncertainty range. The result of the project indicates that the oscillation cup technique is applicable for melt viscosity measurement. Detailed mathematical models of innovative sample ampoule designs were developed to not only determine melt viscosity, but also melt density under certain designs. Measurement uncertainties were analyzed and quantified. The result of this project can be used as the initial step toward the eventual goal of establishing a viscosity measurement system for radioactive melts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development of a Thin-Wall Magnesium side door Inner Panel for Automobiles

Cast magnesium side door inner panels can provide a good combination of weight, functional, manufacturing and economical requirements. However, several challenges exist including casting technology for thin-wall part design, multi-material incompatibility and relatively low strength vs steel. A project has been initiated, supported by the US Department of Energy, to design and develop a lightweight frame-under-glass door having a thin-wall, full die-cast, magnesium inner panel. This development project is the first of its kind within North America. Phase I of the project is now complete and the 2.0mm magnesium design, through casting process enablers, has met or exceeded all stiffness requirements, with significant mass reduction and part consolidation. In addition, a corrosion mitigation strategy has been established using industry-accepted galvanic isolation methods and coating technologies.

36 MATERIALS SCIENCE↗

Sequential Deposition of Organic Films with Eco‐Compatible Solvents Improves Performance and Enables Over 12%‐Efficiency Nonfullerene Solar Cells

Abstract Casting of a donor:acceptor bulk‐heterojunction structure from a single ink has been the predominant fabrication method of organic photovoltaics (OPVs). Despite the success of such bulk heterojunctions, the task ofcontrolling the microstructure in a single casting process has been arduous and alternative approaches are desired. To achieve OPVs with a desirable microstructure, a facile and eco‐compatible sequential deposition approach is demonstrated for polymer/small‐molecule pairs. Using a nominally amorphous polymer as the model material, the profound influence of casting solvent is shown on the molecular ordering of the film, and thus the device performance and mesoscale morphology of sequentially deposited OPVs can be tuned. Static and in situ X‐ray scattering indicate that applying (R)‐(+)‐limonene is able to greatly promote the molecular order of weakly crystalline polymers and form the largest domain spacing exclusively, which correlates well with the best efficiency of 12.5% in sequentially deposited devices. The sequentially cast device generally outperforms its control device based on traditional single‐ink bulk‐heterojunction structure. More crucially, a simple polymer:solvent interaction parameter χ is positively correlated with domain spacing in these sequentially deposited devices. These findings shed light on innovative approaches to rationally create environmentally friendly and highly efficient electronics.

Ye, Long↗

Exploring the Microstructure-Property Relationship of Mg-Al-Mn alloys enhanced via Friction Stir Processing

Friction Stir Processing (FSP) is a solid-state thermomechanical processing technique that enables local grain refinement, densification, and homogenization of microstructure in metallic components. Here, FSP is applied to thin sheets of high-pressure die cast AM60 to address the porosity and heterogeneities inherent to the casting process. In this work, microstructure characterization is correlated to improvements in the static mechanical properties of the Mg-Al-Mn alloy system at various FSP processing conditions. Notably, there is a significant increase in the ductility and ultimate tensile stress of system following FSP. The dominant deformation mechanisms for the as-cast material and the FSP material are investigated. Finally, the fatigue life improvement is correlated to microstructure modifications that may lead to distinct behavior in crack initiation and crack propagation for the as-cast and FSP material.

Garcia, David↗

Transarterial Ethylene Vinyl Alcohol Copolymer Visualization and Penetration After Embolization of Life-Threatening Hemoptysis: Technical and Clinical Outcomes

Objectives: This study was designed to evaluate the feasibility of using ethylene vinyl alcohol copolymer (EVAC) for bronchial artery embolization (BAE) in patients with life-threatening hemoptysis and to compare the visualization and transarterial penetration of EVAC under fluoroscopy and computed tomography (CT). Methods: Fifteen patients (mean age, 62.9 (range, 24-82) years) who were referred for life-threatening hemoptysis (27 month period) underwent BAE using EVAC. All patients had thoracic CT examination before and after BAE. Technical and clinical results were evaluated. Visibility and extent of cast penetration (graded 1-4) on fluoroscopy and postprocedure CT were assessed and compared. Results: BAE was feasible in all but one artery (due to spasm; n = 27; 96.4%). No procedure-related complications or deaths were detected. Two patients had recurrent bleeding in the following day (13.3%). Immediate clinical success was achieved in 14 cases (93.3%) after reembolization of pulmonary artery pseudoaneurysm in one patient (mean follow-up, 43.5 (range, 14-148) days). Visibility of the cast was possible in 73.3% of patients (n = 11) under fluoroscopy (mean cast penetration 1.66) and in all patients under CT (mean cast penetration 2.06). The postinjection fluoroscopic visibility in 6 of 15 (40%) patients was inferior to CT (P < 0.02). Conclusions: BAE with EVAC seems to be feasible and safe with immediate control of hemoptysis in most patients. The postinjection fluoroscopic visibility of EVAC under fluoroscopy was inferior to CT.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

Transhepatic Tract Embolisation After Biliary Intervention Using n-Butyl Cyanoacrylate and Autologous Blood: A Retrospective Analysis of 42 Patients

Purpose: We evaluated the safety and efficacy of transhepatic tract embolisation after a biliary intervention using n-butyl cyanoacrylate (NBCA) and autologous blood. Materials and Methods: Between January 2017 and December 2018, 42 consecutive patients (mean age: 71 ± 15 years, 24 men) with malignant (n = 26) or benign (n = 16) biliary obstructions underwent percutaneous biliary intervention followed by tract embolisation within 2 weeks. Forty-six transhepatic tracts (4 bilateral) in 42 patients were embolised using a NBCA and lipiodol mixtures (1:1–1:2 ratios) after intraductal infusion of peripherally obtained autologous blood. The indwelling catheter diameters were 8.5–14 Fr. The median interval between percutaneous biliary drainage and tract embolisation was 10 days (range 3–14 days). Glue-cast formation via fluoroscopy and immediate complications were reviewed retrospectively in medical records. Follow-up data (median: 135, range 11–720 days) including computed tomography (CT) images (n = 17) were evaluated for delayed complications and glue-cast formation. Results: Successful glue-cast formations were achieved in all 46 tracts. No patients experienced haemorrhage, and only one patient had external bile leakage. Eight patients complained of abdominal pain (numerical scale ≤ 5) immediately after embolisation, which was controlled by analgesics. Two patients had transient fever. Segmental (n = 11) or sub-segmental (n = 6) glue-cast patterns were identified along the transhepatic tract by follow-up CT. No biliary obstructions were caused by inadvertent glue spread. Fragmented glue was detected outside the stent in one patient. Conclusion: Transhepatic parenchymal tract embolisation with NBCA and autologous blood is a safe and feasible method for preventing bile leakage. Level of Evidence: Level 4, Case Series.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

Oxidation Behavior of Heat-Resistant Type $\mathrm{HK}$ Steel ($\mathrm{HK30Nb}$) at 800 °C

We report the cyclic oxidation behavior of HK30Nb heat-resistant steel processed by laser powder bed fusion (LPBF) was compared to its cast counterpart during exposures in air and air + 10% H 2 O at 800 °C. The specific finer microstructure and lower Mn of the LPBF alloy resulted in lower oxidation rates in dry air and faster establishment of a continuous Cr 2 O 3 scale in air + 10% H 2 O compared to coarse-grained cast HK30Nb with higher Mn. Differences in alloy mechanical strength and therefore their ability to accommodate high temperature and oxidation-induced stresses as well as differences in thermal expansion coefficients between the alloy and the formed oxides (Cr 2 O 3 only for the LPBF and Cr 2 O 3 and MnCr 2 O 4 for the cast specimens) during temperature cycling were found to result in a greater extent of spallation for the LPBF than for the cast alloy in dry air at 800 °C.

36 MATERIALS SCIENCE↗

Effect of Mg-Bearing Oxide(+TiN) Inclusion on Microstructure of Fe-16 Mass Pct Cr Ferritic Alloy and Its Evolution During Heating at 1573 K (1300 °C)

Both the effects of Mg-bearing oxide and Mg-bearing oxide +TiN inclusions on the microstructures of Fe-16 mass pct Cr alloy should be clarified. In this paper, the effects of Mg-bearing oxide(+TiN) inclusions on the microstructures of Fe-16 mass pct Cr ferritic alloy and changes due to the inclusions during heating at 1573 K (1300 °C) were studied by manual and automatic SEM-EDS analyses. Three alloys were used as specimens. The inclusions were Al{sub 2}TiO{sub 4} +TiN with a small amount of TiN in alloy #1, Al{sub 2}(Mg, Ti)O{sub 4} in alloy #2 and Al{sub 2}(Mg, Ti)O{sub 4} +TiN in alloy #3. The average grain size was smaller, and the ratio of columnar grains was lower in the as-cast alloy #2 and as-cast alloy #3 than that in the as-cast alloy #1. This is attributed to the heterogeneous nucleation of delta ferrite on Al{sub 2}(Mg, Ti)O{sub 4} during solidification. Refinement of the microstructures of ferritic steel by Mg-bearing oxide + multi-TiN inclusions is proposed. Changes in composition, aspect ratio, and size distribution of inclusions in each alloy during heating were investigated systematically. Mg-bearing oxide(+TiN) was dispersed in both the as-cast alloys and heated alloys, which contributed to microstructural refinement of the heated alloys through the pinning effect.

36 MATERIALS SCIENCE↗

Effects of Scandium Addition and T7 Heat Treatment on Thermal Stability and Corrosion Properties of A201 Alloy

This study elucidates how scandium addition and T7 heat treatment affects thermal stability and corrosion properties of A201 alloy. The as-cast and the T7 heat-treated specimens were thermally exposed at 300 °C for 120 h to investigate the evolution of the Sc-free and the Sc-containing alloys. The results indicated that adding 0.6 wt.% scandium to A201 alloy could produce Al{sub 3}Sc, W phase (Al{sub 8-5.4}Cu{sub 6.6-4}Sc) and grain refinement, significantly enhancing the hardness and tensile strength in as-cast condition. The as-cast A201 alloy containing Sc also showed the least loss of hardness and strength during thermal exposure at 300 °C. In addition, the presence of W phase weakened the peak hardness and tensile strength of the Sc-containing A201 alloy during T7 heat treatment. Adding Sc to A201 alloy increased corrosion resistance in T7 heat-treated condition, but slightly decreased corrosion resistance in as-cast condition.

36 MATERIALS SCIENCE↗

Creep-Resistant Ferritic-Martensitic Steels for Power Plant Applications

Creep-resistant ferritic-martensitic steels are essential materials used in power plants for electricity generation. The efficiency and emissions of the plant are closely related to the operating temperature. Materials used in the hottest sections are one of the main limiting factor for plant operation at 650 °C. This review describes the recent development of creep-resistant ferritic-martensitic steels from a large dataset of in-house research. The findings are tied to available literature for discussion. A first steel, CPJ-7, was developed with an operating temperature approaching 650 °C, and a refined design, JMP, showed the potential to operate at 650 °C. Approximately fifty different ingots, each weighing ~ 7 kg, were vacuum induction melted and processed. Overall, wrought and cast versions of CPJ-7 present superior creep properties when compared to wrought and cast versions of COST alloys for steam turbine and P91/92 for boiler applications. The prolonged creep life was attributed to slowing down the process of the destabilization of the MX and M 23 C 6 precipitates at 650 °C. The cast version of CPJ-7 also revealed superior mechanical performance, above commercially available cast 9% Cr martensitic steel or derivatives. Following the work on CPJ-7, the JMP steels were designed with higher Co for increased solid solution strengthening, Si for oxidation resistance and increased W for matrix strength and stability. The JMP steels showed increases in creep life compared to CPJ-7 between 118 and 150% at 650 °C for testing at various stresses between 138 and 207 MPa. On a Larson–Miller plot, the performance of the JMP steels surpasses that of state-of-the-art MARBN steel. The influence of various elements within the composition of the alloys on the microstructure and mechanical properties is discussed. This review presents approximately 420,000 h of in-house creep testing, the equivalent of almost 50 years of cumulative creep tests.

36 MATERIALS SCIENCE↗

Combining direct ink writing with reactive melt infiltration to create architectured thermoelectric legs

Here, we present a new additive-reactive synthesis method where inks – cast into molds or 3D-additively extruded into architectured shapes – are reacted into intermetallic thermoelectric compounds. The new method, as demonstrated for equiatomic TiNiSn, combines: (i) extrusion printing (or casting) of inks containing Ni and Ti powders, (ii) debinding and reactive sintering to form a porous NiTi network, (iii) network infiltration with liquid Sn and subsequent reaction to synthesize the TiNiSn phase. Thin plates, created through this method, show high phase purity and low residual porosity. A thermoelectric figure of merit zT = 0.47 ± 0.05 is achieved at 800 K, within the broad range of values (zT= 0.3–1.0) reported for TiNiSn created via traditional powder hot-pressing methods. Layered TiNiSn microlattices – after 3D ink-extrusion printing and infiltration – exhibit high relative densities and minimal undesirable secondary phase content, with a Seebeck coefficient on par with the ink-cast TiNiSn plates, demonstrating that thermoelectric legs with far-ranging architectural freedom can be created additively with this novel reactive manufacturing method. Numerous other thermoelectric (and other) compounds, currently limited to basic geometries due to brittleness, are amenable to this new method based on a sequence of reactive sintering/infiltration of cast or ink-extruded precursors.

36 MATERIALS SCIENCE↗