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The topics covered in this slide presentation are: the general approach to software quality improvement (SQI) at Jet Propulsion Institute, the SQI deployment process, and lessons learned in regard to SQI. The Software Engineering Process Group (SEPG) is the group charged with SQI. The initial focus of the Software Quality Improvement (SQI) Project is on mission-critical software for flight projects, their spacecraft and instrument systems, and their ground systems.
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The present invention is directed toward a coating system for electrodepositing a battery electrode coating onto a foil substrate, the system comprising a tank structured and arranged to hold an electrodepositable coating composition; a feed roller positioned outside of the tank structured and arranged to feed the foil into the tank; at least one counter electrode positioned inside the tank, the counter electrode in electrical communication with the foil during operation of the system to thereby deposit the battery electrode coating onto the foil; and an in-line foil drier positioned outside the tank structured and arranged to receive the coated foil from the tank. Also disclosed are methods for electrocoating battery electrode coatings onto conductive foil substrates, coated foil substrates, and electrical storage devices comprising the coated foil substrates.
The present disclosure relates to a tensioning system for use in a stereolithography manufacturing application. The system may have a build plate for supporting a three dimensional part being formed using a photo responsive resin, a base plate and a release element extending over the base plate. The release element is configured to receive a quantity of photo responsive resin for forming a new material layer of the three dimensional part. A pair of tensioning components are secured to opposite ends of the release element, and apply a controlled tension force to the release element during peeling of the release element to reduce a separation force required to separate the release element from the new material layer after the new material layer is cured.
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Over the past several years Pacific Northwest National Laboratory (PNNL) has been actively involved in supporting the U.S. Department of Energy National Nuclear Security Administration Office of Material Management and Minimization (formerly Global Threat Reduction Initiative). The U.S. High- Power Research Reactor (USHPRR) project is developing alternatives to existing highly enriched uranium alloy fuel to reduce the proliferation threat. One option for a high-density metal fuel is uranium alloyed with 10 wt% molybdenum (U-10Mo). Forming the U-10Mo fuel plates/foils via rolling is an effective technique and is actively being pursued as part of the baseline manufacturing process. The processing of these fuel plates requires systematic investigation/understanding of the pre- and post-rolling microstructure, end-state mechanical properties, residual stresses, and defects, their effect on the mill during processing, and eventually, their in-reactor performance. In the work documented herein, studies were conducted to determine the effect of cold and hot rolling the as-cast and homogenized U-10Mo on its microstructure and hardness. The samples were homogenized at 900°C for 48 h, then later annealed for several durations and temperatures to investigate the effect on the material’s microstructure and hardness. The rolling of the as-cast plate, both hot and cold, was observed to form a molybdenum-rich and -lean banded structure. The cold rolling was ineffective, and in some cases exacerbated the as-cast defects. The grains elongated along the rolling direction and formed a pancake shape, while the carbides fractured perpendicularly to the rolling direction and left porosity between fractured particles of UC. The subsequent annealing of these samples at sub-eutectoid temperatures led to rapid precipitation of the ' lamellar phase, mainly in the molybdenum-lean regions. Annealing the samples above the eutectoid temperature did not refine the grain size or the banded microstructure. However, annealing the samples led to quick recovery in hardness as evidenced by a drop in Vickers hardness of 20%. Hot rolling was performed at 650 and 800°C. The hot-rolling mill loads (load separation force) were approximately 40 to 50% less than the cold-rolling for the same reduction and thickness. It was observed that hot rolling the samples with 50% or more reduction in thickness were responsible for dynamic recrystallization in the hot-rolled samples and led to grain refinement. Unlike the cold-rolled samples, the hot-rolled samples did not fracture the carbides and appeared to heal the casting defects. The recovery phenomenon was similar to the cold-rolled samples above the eutectoid temperatures, but owing to the refined grain size, the precipitation of the lamellar phase was far more rapid in these samples and the hardness increased more rapidly than in the cold rolled sample when heated below the eutectoid temperature. The data generated from these rolling efforts has been used to make the process modeling efforts more robust and applicable to all USHPRR partner rolling mills. The flow stress for cold rolling the samples was determined to be between 170-190 ksi, with frictional forces between 0.2 and 0.4 for the PNNL mill. The measured roll separation forces and those simulated using finite element methods for hot and cold rolling for the PNNL rolling mill were in good agreement.
Over the past several years Pacific Northwest National Laboratory (PNNL) has been actively involved in supporting the U.S. Department of Energy National Nuclear Security Administration Office of Material Management and Minimization (formerly Global Threat Reduction Initiative). The U.S. High-Power Research Reactor (USHPRR) project is developing alternatives to existing highly enriched uranium alloy fuel to reduce the proliferation threat. One option for a high-density metal fuel is uranium alloyed with 10 wt% molybdenum (U-10Mo). Forming the U-10Mo fuel plates/foils via rolling is an effective technique and is actively being pursued as part of the baseline manufacturing process. The processing of these fuel plates requires systematic investigation/understanding of the pre- and post-rolling microstructure, end-state mechanical properties, residual stresses, and defects, their effect on the mill during processing, and eventually, their in-reactor performance. In the work documented herein, studies were conducted to determine the effect of cold and hot rolling the as-cast and homogenized U-10Mo on its microstructure and hardness. The samples were homogenized at 900°C for 48 h, then later annealed for several durations and temperatures to investigate the effect on the material’s microstructure and hardness. The rolling of the as-cast plate, both hot and cold, was observed to form a molybdenum-rich and -lean banded structure. The cold rolling was ineffective, and in some cases exacerbated the as-cast defects. The grains elongated along the rolling direction and formed a pancake shape, while the carbides fractured perpendicularly to the rolling direction and left porosity between fractured particles of UC. The subsequent annealing of these samples at sub-eutectoid temperatures led to rapid precipitation of the α + γ ' lamellar phase, mainly in the molybdenum-lean regions. Annealing the samples above the eutectoid temperature did not refine the grain size or the banded microstructure. However, annealing the samples led to quick recovery in hardness as evidenced by a drop in Vickers hardness of 20%. Hot rolling was performed at 650 and 800°C. The hot-rolling mill loads (load separation force) were approximately 40 to 50% less than the cold-rolling for the same reduction and thickness. It was observed that hot rolling the samples with 50% or more reduction in thickness were responsible for dynamic recrystallization in the hot-rolled samples and led to grain refinement. Unlike the cold-rolled samples, the hot-rolled samples did not fracture the carbides and appeared to heal the casting defects. The recovery phenomenon was similar to the cold-rolled samples above the eutectoid temperatures, but owing to the refined grain size, the precipitation of the lamellar phase was far more rapid in these samples and the hardness increased more rapidly than in the cold rolled sample when heated below the eutectoid temperature. The data generated from these rolling efforts has been used to make the process modeling efforts more robust and applicable to all USHPRR partner rolling mills. The flow stress for cold rolling the samples was determined to be between 170-190 ksi, with frictional forces between 0.2 and 0.4 for the PNNL mill. The measured roll separation forces and those simulated using finite element methods for hot and cold rolling for the PNNL rolling mill were in good agreement.
A focus of the U.S. Department of Energy is to improve production yield and reduce the cost of Low Enriched Uranium (LEU)-molybdenum alloy (U-10Mo) monolithic fuel plates that will be replacing High Enriched Uranium (HEU) oxide dispersion fuels used currently in the United States High Performance Research Reactors (USHPRR). One area of improvement is lowering the high transverse waviness and longitudinal waviness currently present within rolled foils prior to cladding to produce fuel plates. Traditional rolling manufacturing techniques for other metal foils use winders to pull and straighten the foil as it is rolled back and forth to the final thickness. This approach cannot be used to roll thin U-10Mo foils (0.008-0.025” thick) because only small castings can be rolled due to nuclear criticality safety concerns. As a result, the fuel foils are too short (1 m in length) to use traditional winders. Therefore, it is crucial to identify other rolling parameters (i.e., roller friction, axial tension load, roller diameter, and roll pass reduction percent) that might reduce transverse waviness and longitudinal waviness in the rolled fuel foil and develop a high-yield, low-cost multi-pass rolling manufacturing process. This report documents a systematic finite element modeling study to investigate the effects of numerous rolling parameters to reduce resulting transverse waviness and longitudinal waviness in the fuel foil during multi-pass rolling of U-10Mo foils. The rolling of a U-10Mo plate with initial dimensions of 1”x1”x 0.048” is modeled using Abaqus CAE. This rolling is modeled to undergo eight 20% reduction roll passes to a final fuel foil thickness of 0.01”. The elastic-plastic constitutive model of the U-10Mo alloy was input to the fuel foil rolling model. The rollers were modeled as rigid bodies. A comparison of rolling friction coefficients of 0.3 and 0.7 over a wide range of applied axial tension loads were investigated in order to evaluate the effect of using a lubricant during rolling. The effect of roller diameter on the resulting transverse waviness and longitudinal waviness of the fuel foil over a wide range of axial tension loads were also investigated by modeling rollers 7/8” and 3.75” in diameter. The results of this systematic finite element method study will aid manufacturers in producing low transverse waviness and reduced longitudinal waviness in U-10Mo fuel foils.
It is difficult to fabricate magnesium alloy sheets at room temperature due to their hexagonal close-packed structure. In this paper, we proposed a new process that can be used to fabricate AZ31 magnesium alloy sheets with fine-grained microstructure and good mechanical properties. AZ31 magnesium alloy sheets with dimensions of 160 mm × 8 mm were obtained successfully by a continuous extrusion technique. The extruded sheets were then rolled by two different rolling routes, Route 1: the extruded sheet was heated at 350 °C and then rolled without heating of rolls and Route 2: the sheet was rolled without any previous heating by heating rolls at 280 °C. The microstructure and texture evolution as well as mechanical properties of the continuously extruded and rolled sheets were examined experimentally. The magnesium alloy sheets with relatively fine grains of 4.5-8.3 µm were obtained by continuous extrusion followed by rolling processes. The tensile strength of continuously extruded AZ31 Mg alloy sheets can be effectively increased by rolling using heating rolls (Route 2), while the ductility was enhanced by rolling heated sheets (Route 1). The mixed microstructure, consisting of refined DRX grains and deformed grains, contributes to enhancement in tensile strength of the sheet samples rolled by Route 2 due to grain-boundary strengthening and work hardening. Lower temperature and larger rolling reduction are two main factors for improving the tensile strength of AZ31magnesium alloy sheets.
In order to evaluate the viability of ShAPE processed Mg alloys as a feedstock for fabricating lightweight sheet material, tubes consisting of ShAPE-extruded Mg alloy ZK60 were flattened into plates and hot rolled at 450 °C to reductions of 37%, 68%, and 93%. The mechanical properties and microstructure of the rolled material were characterized through tensile testing and electron backscattered diffraction (EBSD). ZK60 specimens rolled to 68% reduction had tensile properties similar to published properties of rolled ZK60 sheets fabricated using conventional processes, and exhibited negligible tensile anisotropy referenced to the rolling direction. Additional rolling from 68% to 93% reduced the ultimate tensile stress in the rolling direction from 341.74±5.96 MPa to 260.76±22.4MPa. The yield stress and elongation to failure of the material also decreased from 292.16±1.11 MPa to 256.93±18.4 MPa and 6.95±1.94% to 3.38±0.51%, respectively, but negligible little anisotropy was observed with respect to loading direction. EBSD mapping indicated that the as-extruded ZK60 had texture rotated away from the basal direction which developed into a strong basal texture over numerous hot rolling steps. This evolution in texture has been observed after rolling for hot-rolled ZK60 fabricated through conventional extrusion processes. The initial grain structure was found to have experienced noticeable twinning from flattening the tube into plate. After hot rolling, the grain structure became more equiaxed, but the average grain diameter did not change appreciably from 5.15 ± 3.39 µm in the ShAPE extruded material, to 5.27 ± 12.44 µm in the 93% hot rolled sheet. This response to hot rolling is similar to the response of ZK60 fabricated using other methods such as Equal Channel Angular Processing (ECAP). Therefore, this work demonstrates ShAPE has the potential as an alternative method to producing feedstock for Mg alloy sheets. Modifications to the experimental procedure which could lead to improvements in observed properties are briefly discussed.
In this work, cold rolling behavior of stainless steel 304L is investigated and the effects of different process parameters on the occurrence of strain-induced martensite and mechanical properties are studied. The rolling experiments are conducted under different rolling speeds and reductions in which a set of samples is deformed at room temperature and the other set is first cooled to the temperature of − 10 °C and then rolled. Afterward, the developed microstructures and mechanical properties of the rolled steel are evaluated employing different testing techniques. In order to justify the results, mathematical modeling of cold rolling operation is also performed using Abaqus/Explicit to estimate the distribution of equivalent plastic strain and temperature rise during rolling. The results show that strain-induced martensite may occur during cold rolling and it efficiently alters microstructure and mechanical performance of the rolled plate. The amount of reduction, initial temperature, rolling layout, and, to a lesser extent, rolling speed can affect the kinetics of martensite transformation as well as microstructure and mechanical properties of the rolled steel.
Highlights: • Sn microalloying contributes to the enhancement in cold rolling texture intensity and the acceleration in cold rolling texture transformation. • Sn microalloying promotes the recrystallization process, and recrystallization occurs preferentially in steel with Sn compared with Sn-free steel. • Sn microalloying inhibits the growth of recrystallized grains, and the finer grains are obtained in steel with Sn. - Abstract: We investigated the effects of Sn microalloying on cold rolling and recrystallization textures and microstructure of a ferritic stainless steel. The as-received hot rolled sheets were cold rolled at 10%–90% reductions; the sheets cold rolled up to an 80% reduction were annealed at 740–880 °C for 5 min. For comparison, the cold rolling and recrystallization textures of the steel sheets with and without Sn were determined with the conventional X-ray diffraction method. The cold rolling and recrystallization metallographic microstructures were measured by scanning electron microscope and optical microscope, and the crystal orientation maps of the cold rolled and annealed samples were observed by electron backscattered diffraction. The micro-hardness was determined using a digital micro-hardness tester. Our results show that Sn microalloying in a medium chromium ferritic stainless steel plays multiple roles in the cold rolling and recrystallization processes. Sn micrcoalloying contributes to the enhancement in cold rolling texture intensity and the acceleration in cold rolling texture transformation. Sn microalloying is beneficial in promoting the recrystallization process. Recrystallization occurs preferentially in the ferritic stainless steel with Sn. Sn microalloying plays an important role in inhibiting the growth of recrystallized grains. The finer grains are obtained in ferritic stainless steel with Sn when annealing at high temperatures.
We study the corrections to the power spectra of curvature and tensor perturbations and the tensor-to-scalar ratio r in single field slow roll inflation with standard kinetic term due to initial conditions imprinted by a ''fast-roll'' stage prior to slow roll. For a wide range of initial inflaton kinetic energy, this stage lasts only a few e-folds and merges smoothly with slow-roll thereby leading to non-Bunch-Davies initial conditions for modes that exit the Hubble radius during slow roll. We describe a program that yields the dynamics in the fast-roll stage while matching to the slow roll stage in a manner that is independent of the inflationary potentials. Corrections to the power spectra are encoded in a ''transfer function'' for initial conditions T{sub α}(k), P{sub α}(k) = P{sup BD}{sub α}(k)T{sub α}(k), implying a modification of the ''consistency condition'' for the tensor to scalar ratio at a pivot scale k{sub 0}: r(k{sub 0}) = −8n{sub T}(k{sub 0}) [T{sub T}(k{sub 0})/T{sub R}(k{sub 0})]. We obtain T{sub α}(k) to leading order in a Born approximation valid for modes of observational relevance today. A fit yields T{sub α}(k) = 1+A{sub α}k{sup −p}cos [2πωk/H{sub sr}+φ{sub α}], with 1.5∼<p∼<2, ω ≅ 1 and H{sub sr} the Hubble scale during slow roll inflation, where curvature and tensor perturbations feature the same p,ω for a wide range of initial conditions. These corrections lead to both a suppression of the quadrupole and oscillatory features in both P{sub R}(k) and r(k{sub 0}) with a period of the order of the Hubble scale during slow roll inflation. The results are quite general and independent of the specific inflationary potentials, depending solely on the ratio of kinetic to potential energy κ and the slow roll parameters ε{sub V}, η{sub V} to leading order in slow roll. For a wide range of κ and the values of ε{sub V}; η{sub V} corresponding to the upper bounds from Planck, we find that the low quadrupole is consistent with the results from Planck, and the oscillations in r(k{sub 0}) as a function of k{sub 0} could be observable if the modes corresponding to the quadrupole and the pivot scale crossed the Hubble radius very few (2–3) e-folds after the onset of slow roll. We comment on possible impact on the recent BICEP2 results.
Quadrupole rolls (i.e. rotation around the magnet axis) are known to be a significant source of image blurring in magnetic quadrupole lenses. These rolls may be caused by errors in mechanical mounting of quadrupoles, by uneven radiation-induced demagnetization of permanent-magnet quadrupoles, etc. Here a four-quadrupole ×10 lens with so-called ”Russian” or A -B B-A symmetry is used as a model problem. Existing SLAC 1/2 in. bore high-gradient quadrupoles are used in the design. The dominant quadrupole roll effect is changes in the first-order part of the transfer map (the R matrix) from the object to the image plane (Note effects on the R matrix can be of first order in rotation angle for some R-matrix elements and second order in rotation angle for other elements, as shown below). It is possible to correct roll-induced image blur by mechanically adjusting the roll angle of one or more of the quadrupoles. Usually, rotation of one quadrupole is sufficient to correct most of the combined effect of rolls in all four quadrupoles. There are drawbacks to this approach, however, since mechanical roll correction requires multiple entries into experimental area to make the adjustments, which are made according to their effect on images. An alternative is to use a single electromagnetic skew quadrupole corrector placed either between two of the quadrupoles or after the fourth quadrupole (so-called “non-local” correction). The basic feasibility of skew quadrupole correction of quadrupole roll effects is demonstrated here. Rolls of the third lens quadrupole of up to about 1 milliradian can be corrected with a 15 cm long skew quadrupole with a gradient of up to 1 T/m. Since the effect of rolls of the remaining three lens quadrupoles are lower, a weaker skew quadrupole can be used to correct them. Non-local correction of quadrupole roll effects by skew quadrupoles is shown to be about one-half as effective as local correction (i.e. rotating individual quadrupoles to zero roll angle or placing skew quadrupole correctors in the bores of main quadrupoles).