Recent Developments in Cast Alumina-Forming Austenitic Stainless Steel Furnace Rolls
Explore the source record for details and available documents.
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.
Explore the source record for details and available documents.
Paper to be submitted to SPIE'24: Optics and Photonics. I'll will also be presenting the contents of this paper in talk at the conference.
Explore the source record for details and available documents.
Highlights: • Microstructure of roll coating developed on a ground steel work roll was examined. • Roll coating was formed during the 20 pass hot rolling schedule of an Al-Mg alloy. • The roll coating had a complex layered nanocrystalline and amorphous structure. • The roll coating layers were composed of metallic Al, porous MgO and C. • Work roll debris, Fe and Cr, were observed embedded within the roll coating. - Abstract: The microstructure and composition of a roll coating built-up on an AISI M2 steel work roll during a 20 pass hot rolling schedule using a laboratory rolling tribo-simulator with a roll-on-block configuration was examined. The AISI M2 steel work roll was characterized by grinding grooves and possessed a surface roughness (R{sub a}) of 0.17 μm. The roll coating developed under these lubricated conditions was discontinuous, patchy and streaked out in the rolling direction. The microstructure and chemical composition of the material transfer that made up the roll coating was analysed and revealed to possess a complex composite microstructure consisting of nanocrystalline aluminum, nanocrystalline/amorphous MgO and amorphous carbon layers. The nanocrystalline MgO layers were porous structures lying between the solid metallic aluminum layers. Debris particles from the wear of the work roll were detected embedded within the carbon layer and at the base of the roll coating. The microstructure of the roll coating appear to be determined by the deformation conditions experienced during the rolling process, while its composition is dependent on the composition of the rolled alloy, the work roll and the lubrication conditions employed.
The Tropical Rainfall Measuring Mission (TRMM) spacecraft, a joint mission between the U.S. and Japan, launched onboard an HI1 rocket on November 27,1997 and transitioned in August, 2001 from an average operating altitude of 350 kilometers to 402.5 kilometers. Due to problems using the Earth Sensor Assembly (ESA) at the higher altitude, TRMM switched to a backup attitude control mode. Prior to the orbit boost TRMM controlled pitch and roll to the local vertical using ESA measurements while using gyro data to propagate yaw attitude between yaw updates from the Sun sensors. After the orbit boost, a Kalman filter used 3-axis gyro data with Sun sensor and magnetometers to estimate onboard attitude. While originally intended to meet a degraded attitude accuracy of 0.7 degrees, the new control mode met the original 0.2 degree attitude accuracy requirement after improving onboard ephemeris prediction and adjusting the magnetometer calibration onboard. Independent roll attitude checks using a science instrument, the Precipitation Radar (PR) which was built in Japan, provided a novel insight into the pointing performance. The PR data helped identify the pointing errors after the orbit boost, track the performance improvements, and show subtle effects from ephemeris errors and gyro bias errors. It also helped identify average bias trends throughout the mission. Roll errors tracked by the PR from sample orbits pre-boost and post-boost are shown in Figure 1. Prior to the orbit boost the largest attitude errors were due to occasional interference in the ESA. These errors were sometime larger than 0.2 degrees in pitch and roll, but usually less, as estimated from a comprehensive review of the attitude excursions using gyro data. Sudden jumps in the onboard roll show up as spikes in the reported attitude since the control responds within tens of seconds to null the pointing error. The PR estimated roll tracks well with an estimate of the roll history propagated using gyro data. After the orbit boost, the attitude errors shown by the PR roll have a smooth sine-wave type signal because of the way that attitude errors propagate with the use of gyro data. Yaw errors couple at orbit period to roll with '/4 orbit lag. By tracking the amplitude, phase, and bias of the sinusoidal PR roll error signal, it was shown that the average pitch rotation axis tends to be offset from orbit normal in a direction perpendicular to the Sun direction, as shown in Figure 2 for a 200 day period following the orbit boost. This is a result of the higher accuracy and stability of the Sun sensor measurements relative to the magnetometer measurements used in the Kalman filter. In November, 2001 a magnetometer calibration adjustment was uploaded which improved the pointing performance, keeping the roll and yaw amplitudes within about 0.1 degrees. After the boost, onboard ephemeris errors had a direct effect on the pitch pointing, being used to compute the Earth pointing reference frame. Improvements after the orbit boost have kept the the onboard ephemeris errors generally below 20 kilometers. Ephemeris errors have secondary effects on roll and yaw, especially during high beta angle when pitch effects can couple into roll and yaw. This is illustrated in figure 3. The onboard roll bias trends as measured by PR data show correlations with the Kalman filter's gyro bias error. This particularly shows up after yaw turns (every 2 to 4 weeks) as shown in Figure 3, when a slight roll bias is observed while the onboard computed gyro biases settle to new values. As for longer term trends, the PR data shows that the roll bias was influenced by Earth horizon radiance effects prior to the boost, changing values at yaw turns, and indicated a long term drift as shown in Figure 4. After the boost, the bias variations were smaller and showed some possible correlation with solar beta angle, probably due to sun sensor misalignment effects.
The overall goal of this project is to enhance the formability of Nanostructured Ferritic Alloys (NFAs) such that high-strength thin-walled claddings can be successfully and economically manufactured for use in future nuclear reactors. Specifically, four objectives were identified: Objective #1 – to achieve a good understanding of the mechanical behavior and resulting microstructure of 14YWT made from the powder form subjected to various Electrically- Assisted (EA) loading conditions. Objective #2 – to conduct EA-flat rolling of 14YWT completed and the prioritization/selection of two alternative designs of EA tube rolling processes. Objective #3 – to design and assemble a new EA tube rolling machine. Objective #4 – to conduct rolling using the new EA rolling machine. The above objectives were achieved and the findings can be further applied to establish other innovative fabrication processes. Specifically, the major accomplishments are summarized as: The use of an EA forming process was investigated to reduce the forming force of ODS ferritic steels. The effect of a continuous electric current on 14YWT during plastic deformation was evaluated. EA uniaxial tension tests show that the electric current is able to reduce the flow stress of 14YWT. 14YWT exhibits a ductility minimum at a current density of 34.5 A/mm2 which is consistent with fractography results. Hardness measurements and TEM results indicate that oxide particles are stable during the EA process. By following the tests, microstructure analysis was performed on the sample in its as-received state and after current treatment. The microstructures are stable when subjected to high current density. The related thermal model was developed to predict the Joule heating temperatures. The temperatures were compared with the experimental results. At last, a temperature-dependent hardening model was used to explore the mechanisms acting during EA deformation. Since the model can accurately predict the yield strength of 14YWT under EA conditions without the incorporation of non-thermal effects, it can be concluded that the reduction in yield strength is due to the Joule heating generated under continuous current loading conditions. An oven-heated pure thermal tension test was conducted to confirm this conclusion. The new EA tube rolling machine has been completely developed. The related work includes: (1) forming process design; (2) analysis of the effect of roll-tube contact geometry on rolling force; (3) analysis of machine performance under mechanical loading; (4) design of machine electrical setting path and insulation; (5) multi-pass process analysis; (6) design of power transmission system (axial/radial/torque feeding mechanisms), roll bearing system, cooling system, workpiece feeding mechanism, and other related mechanical connection support components; (7) design and optimization of roll profiles/dimensions; (8) analysis and simulation of the rolling process; (9) development of engineering drawings and fabrication; (10) assembly and calibration of the EA tube rolling machine; (11) design and integration of the electrical control system; (12) hardware integration for high power supply electrically-assisted rolling process; (13) induction heating system integration; (14) experimental tests for the new rolling process. Through the process from conceptual design to final machine calibration and experimental tests, there are many technical and physical works that have been implemented and improved for the best performance of the innovative prototype.
Low-enriched uranium alloyed with 10 wt% molybdenum (U-10Mo) has been identified as a promising alternative to highly enriched uranium as fuel for the nation’s high-performance research reactors. Manufacturing the U-10Mo alloy consists of multiple complex thermomechanical processes, which is highly challenging for computational modeling. The integrated computational materials engineering (ICME) concept supports building a microstructure-based framework to investigate the effect of manufacturing processes on the material microstructure. In this report, an ICME model that combines homogenization, hot rolling, annealing, and cold rolling is presented as an example of implementing the ICME concept for modeling the manufacturing processes of the U-10Mo alloy. The integrated model enables information to be passed between the different model components, leading to an improved prediction and a better understanding of microstructure across multiple processes. The integrated model was also implemented to investigate the variation of chemical composition, thickness of the zirconium interlayer, grain growth, and carbide redistribution and fracture of U-10Mo during the thermomechanical processes. With the homogenization model, a molybdenum concentration map can be reconstructed from any given microstructure, and the homogenization time needed to reach a desired homogenization level can also be approximated. The microstructure-based finite-element rolling model, shows that the homogenization process reduces the nonuniformity in the thickness of the zirconium interlayers on the U-10Mo. With the output from the rolling model, a statistical analysis of second-phase hard particles was conducted to quantify the particle redistribution and interparticle spacing between carbides during the deformation. Also, new stringer identification criteria were proposed to predict the correlation between stringer volume fractions and hot-rolling reduction. A macro-finite-element method hot-rolling model showed that higher reduction passes can be achieved within the mill separation force range, and a new “aggressive” rolling schedule was proposed. The model also showed the importance of can material on the quality of rolled foils, with stronger can materials resulting in hot-rolled U-10Mo free of defects (waviness, dog-boning). The deformation-induced recrystallization model demonstrated capability to use inputs from deformation simulations of strain accumulation in U-10Mo samples to predict grain growth behavior of the fuel during thermal treatment stages. Finally, a plane-strain compression mode simulated particle fracture and calculates the void volume fraction generated during cold rolling. The macro-finite-element method cold-rolling model showed that smaller diameter rolls are necessary to achieve the desired foil thickness.
A conical Euler code was developed to study unsteady vortex-dominated flows about rolling highly-swept delta wings, undergoing either forced or free-to-roll motions including active roll suppression. The flow solver of the code involves a multistage Runge-Kutta time-stepping scheme which uses a finite volume spatial discretization of the Euler equations on an unstructured grid of triangles. The code allows for the additional analysis of the free-to-roll case, by including the rigid-body equation of motion for its simultaneous time integration with the governing flow equations. Results are presented for a 75 deg swept sharp leading edge delta wing at a freestream Mach number of 1.2 and at alpha equal to 10 and 30 deg angle of attack. A forced harmonic analysis indicates that the rolling moment coefficient provides: (1) a positive damping at the lower angle of attack equal to 10 deg, which is verified in a free-to-roll calculation; (2) a negative damping at the higher angle of attack equal to 30 deg at the small roll amplitudes. A free-to-roll calculation for the latter case produces an initially divergent response, but as the amplitude of motion grows with time, the response transitions to a wing-rock type of limit cycle oscillation. The wing rocking motion may be actively suppressed, however, through the use of a rate-feedback control law and antisymmetrically deflected leading edge flaps. The descriptions of the conical Euler flow solver and the free-to-roll analysis are presented. Results are also presented which give insight into the flow physics associated with unsteady vortical flows about forced and free-to-roll delta wings, including the active roll suppression of this wing-rock phenomenon.
The Tropical Rainfall Measuring Mission (TRMM) spacecraft, a joint mission between the U.S. and Japan, launched onboard an H-I1 rocket on November 27, 1997, and transitioned in August, 2001, from an average operating altitude of 350 kilometers to 402.5 kilometers. Due to problems using the Earth Sensor Assembly (ESA) at the higher altitude, TRMM switched to a backup attitude control mode. Prior to the orbit boost TRMM controlled pitch and roll to the local vertical using ESA measurements while using gyro data to propagate yaw attitude between yaw updates from the Sun sensors. After the orbit boost, a Kalman filter used 3-axis gyro data with Sun sensor and magnetometers to estimate onboard attitude. While originally intended to meet a degraded attitude accuracy of 0.7 degrees, the new control mode met the original 0.2 degree attitude accuracy requirement after improving onboard ephemeris prediction and adjusting the magnetometer calibration onboard. Independent roll attitude checks using a science instrument, the Precipitation Radar (PR) which was built in Japan, provided a novel insight into the pointing performance. The PR data helped identify the pointing errors after the orbit boost, track the performance improvements, and show subtle effects from ephemeris errors and gyro bias errors. It also helped identify average bias trends throughout the mission. Roll errors tracked by the PR from sample orbits pre-boost and post-boost are shown in Figure 1. Prior to the orbit boost, the largest attitude errors were due to occasional interference in the ESA. These errors were sometime larger than 0.2 degrees in pitch and roll, but usually less, as estimated from a comprehensive review of the attitude excursions using gyro data. Sudden jumps in the onboard roll show up as spikes in the reported attitude since the control responds within tens of seconds to null the pointing error. The PR estimated roll tracks well with an estimate of the roll history propagated using gyro data. After the orbit boost, the attitude errors shown by the PR roll have a smooth sine-wave type signal because of the way that attitude errors propagate with the use of gyro data. Yaw errors couple at orbit period to roll with 1/4 orbit lag. By tracking the amplitude, phase, and bias of the sinusoidal PR roll error signal, it was shown that the average pitch rotation axis tends to be offset from orbit normal in a direction perpendicular to the Sun direction, as shown in Figure 2 for a 200 day period following the orbit boost. This is a result of the higher accuracy and stability of the Sun sensor measurements relative to the magnetometer measurements used in the Kalman filter. In November, 2001 a magnetometer calibration adjustment was uploaded which improved the pointing performance, keeping the roll and yaw amplitudes within about 0.1 degrees.
As part of a continuing NASA program of research on airplane handling qualities, a pilot opinion investigation has been made on the lateral control requirements of fighter aircraft flying in their combat speed range. The investigation was carried out using a stationary flight simulator and a moving flight simulator, and the flight simulator results were supplemented by research tests in actual flight. The flight simulator study was based on the presumption that the pilot rates the roll control of an airplane primarily on a single-degree-of-freedom basis; that is, control of angle of roll about the aircraft body axis being of first importance. From the assumption of a single degree of freedom system it follows that there are two fundamental parameters which govern the airplane roll response, namely the roll damping expressed as a time constant and roll control power in terms of roll acceleration. The simulator study resulted in a criterion in terms of these two parameters which defines satisfactory, unsatisfactory, and unacceptable roll performance from a pilot opinion standpoint. The moving simulator results were substantiated by the in-flight investigation. The derived criterion was compared with the roll performance criterion based upon wing tip helix angle and also with other roll performance concepts which currently influence the roll performance design of military fighter aircraft flying in their combat speed range.
A self clamping cutting tool which includes a handle attached to a C-shaped housing is described. Rotatably mounted within the housing is a C-shaped tool body carrying a set of clamping rolls, two support rolls, and an edged cutting roll (64). The support rolls are disposed to one side of the axis of a pipe and the cutting roll is disposed to the other side of a pipe axis so that these rolls contact a pipe at three circumferential points. Cutter advancing apparatus advance the cutting roll toward the support rollers. The support rolls and cutting roll are rotatable independently of the C-shaped housing. A one way ratchet mechanism disposed between the C-shaped housing and the C-shaped tool body permits operation by movement in one rotational direction about the pipe axis.
The effect of vehicle configuration and flight control system performance on the roll agility of a modern fighter aircraft has been investigated. A batch simulation of a generic F-18 Hornet was used to study the roll agility as measured by the time to roll through 90 deg metric. Problems discussed include definition of agility, factors affecting the agility of a vehicle, the development of the time to roll through 90 deg agility metric, and a simulation experiment. It is concluded that the integral of stability or wind axis roll rate should be used as a measure of the roll measure traversed. The time through roll angle 90 deg metric is considered to be a good metric for measuring the transient performance aspect of agility. Roll agility of the F-18, as measured by 90 deg metric, can be improved by 10 to 30 percent. Compatible roll and rudder actuator rates can significantly affect 90 deg agility metric.
The unsteady, three-dimensional Navier-Stokes equations coupled with the Euler equations of rigid-body dynamics are sequentially solved to simulate and analyze the aerodynamic response of a high angle of attack delta wing undergoing oscillatory motion. The governing equations of fluid flow and dynamics of the multidisciplinary problem are solved using a time-accurate solution of the laminar, unsteady, compressible, full Navier- Stokes equations with the implicit, upwind, Roe flux-difference splitting, finite-volume scheme and a four-stage Runge-Kutta scheme, respectively. The primary model under consideration consists of a 65 deg swept, sharp-edged, cropped delta wing of zero thickness at 20 deg angle of attack. In a freestream of Mach 0.85 and Reynolds number of 3.23 x 10(exp 6), the flow over the upper surface of the wing develops a complex shock system which interacts with the leading-edge primary vortices producing vortex breakdown. The effect of the oscillatory motion of the wing on the vortex breakdown and overall aerodynamic response is detailed to provide insight to the complicated physics associated with unsteady flows and the phenomenon of wing rock. Forced sinusoidal single and coupled mode rolling and pitching motion is presented for the wing in a transonic freestream. The Reynolds number, frequency of oscillation, and the phase angle are varied. Comparison between the single and coupled mode forced rolling and pitching oscillation cases illustrate the effects of coupling the motion. This investigation shows that even when coupled, forced rolling oscillation at a reduced frequency of 2(pi) eliminates the vortex breakdown which results in an increase in lift. The coupling effect for in phase forced oscillations show that the lift coefficient of the pitching-alone case and the rolling-moment coefficient of the rolling-alone case dominate the resulting response. However, with a phase lead in the pitching motion, the coupled motion results in a non-periodic response of the rolling moment. The second class of problems involve releasing the wing in roll to respond to the flowfield. Two models of sharp-edged delta wings, the previous 65 deg swept model and an 80 deg swept, sharp-edged delta wing, are used to observe the aerodynamic response of a wing free to roll in a transonic and subsonic freestream, respectively. These cases demonstrate damped oscillations, self-sustained limit cycle oscillations, and divergent rolling oscillations. Ultimately, an active control model using a mass injection system was applied on the surface of the wing to suppress the self-sustained limit cycle oscillation known as wing rock. Comparisons with experimental investigations complete this study, validating the analysis and illustrating the complex details afforded by computational investigations.
This paper will summarize recent progress in the numerical simulation of high incidence vortical flow about a generic 65 degree sweep delta wing using the three dimensional, time-dependent, Reynolds averaged, Navier-Stokes (RANS) equations. Computations have been carried out at 15 and 30 degrees angle of attack under subsonic turbulent flow conditions, and compared with experimental data provided by Hanff, Jenkins, and their colleagues. This work has already been published elsewhere and widely disseminated. Computations carried out at 15 degrees angle of attack included static roll angles ranging up to 65 degrees, and a large-amplitude (40 degree), high rate (7 Hz), forced roll motion. There was very good agreement between computed and experimental forces and moments, and static surface pressures. There was a significant hysteresis of the dynamic rolling moment due to the high rate of roll motion. At this angle of attack, no vortex breakdown was observed in the computations or experiment. Computations were also carried out at 30 degrees angle of attack, where vortex breakdown was present in both the computations and experiment. There was overall good agreement in the computed and experimental forces and moments. The static rolling moment varied with roll angle in a highly nonlinear manner, and exhibited three stable trim points and two unstable trim points. This behavior was attributed to the presence of vortex breakdown. Two large-amplitude (30 degrees), high-rate (10 Hz) forced roll motions were computed. The dynamics of the vortex breakdown motion was dramatically visualized by tracking the time-dependent motion of particles released near the delta wing apex. This numerical visualization is analogous to experimental smoke flow techniques. In one of the dynamic cases the breakdown was found to move off the wing, convected downwind of the trailing edge, and later reformed near the trailing edge through an instability of the vortex core. A damped free-to-roll motion was also computed by releasing the wing from rest at 40 degrees of roll. The wing went to the same trim point as in the experiment.
A viewgraph presentation of flight tests performed on the F/A active aeroelastic wing airplane is shown. The topics include: 1) F/A-18 AAW Airplane; 2) F/A-18 AAW Control Surfaces; 3) Flight Test Background; 4) Roll Control Effectiveness Regions; 5) AAW Design Test Points; 6) AAW Phase I Test Maneuvers; 7) OBES Pitch Doublets; 8) OBES Roll Doublets; 9) AAW Aileron Flexibility; 10) Phase I - Lessons Learned; 11) Control Law Development and Verification & Validation Testing; 12) AAW Phase II RFCS Envelopes; 13) AAW 1-g Phase II Flight Test; 14) Region I - Subsonic 1-g Rolls; 15) Region I - Subsonic 1-g 360 Roll; 16) Region II - Supersonic 1-g Rolls; 17) Region II - Supersonic 1-g 360 Roll; 18) Region III - Subsonic 1-g Rolls; 19) Roll Axis HOS/LOS Comparison Region II - Supersonic (open-loop); 20) Roll Axis HOS/LOS Comparison Region II - Supersonic (closed-loop); 21) AAW Phase II Elevated-g Flight Test; 22) Region I - Subsonic 4-g RPO; and 23) Phase II - Lessons Learned
A control system for forming a tapered structure includes a sensor providing feedback for a machine for forming a tapered structure including at least three rolls having at least one bend roll and at least two guide rolls. The guide rolls may include rollette banks having a plurality of rollettes. The machine may also include an adjustment mechanism to position at least one of the rolls, where a diameter of the tapered structure being formed is controlled by relative positions of the rolls. The machine may also include a joining element to join edges of a stock of material together as it is rolled through the rolls to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and to send a control signal based on the feedback to the adjustment mechanism for positioning at least one of the rolls.
A control system for forming a tapered structure includes a sensor providing feedback for a machine for forming a tapered structure including at least three rolls having at least one bend roll and at least two guide rolls. The guide rolls may include rollette banks having a plurality of rollettes. The machine may also include an adjustment mechanism to position at least one of the rolls, where a diameter of the tapered structure being formed is controlled by relative positions of the rolls. The machine may also include a joining element to join edges of a stock of material together as it is rolled through the rolls to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and to send a control signal based on the feedback to the adjustment mechanism for positioning at least one of the rolls.
We demonstrate a twofold increase in the in-field critical current of AMSC's standard 2G coil wire by irradiation with 18-MeV Au ions. The optimum pinning enhancement is achieved with a dose of 6 × 10 11 Au ions/cm 2 . Although the 77 K, self-field critical current is reduced by about 35%, the in-field critical current (H//c) shows a significant enhancement between 4 and 50 K in fields > 1 T. The process was used for the roll-to-roll irradiation of AMSC's standard 46-mm-wide production coated conductor strips, which were further processed into standard copper laminated coil wire. The long-length wires show the same enhancement as attained with short static irradiated samples. The roll-to-roll irradiation process can be incorporated in the standard 2G wire manufacturing, with no modifications to the current process. In conclusion, the enhanced performance of the wire will benefit rotating machine and magnet applications.