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At least 19 records

A crucible salt saturation method for determining sulfur solubility in glass melt

Experiments were conducted to determine sulfur solubility in Hanford low-activity waste (LAW) glass melts by a sulfur saturation method. Sulfur-incorporated glass melts were prepared by salt saturation and bubbling methods. The salt saturation method was performed by mixing crushed pre-melted baseline glasses with an excess amount of Na2SO4 prior to melting the mixture at 1150°C for one hour. The bubbling method involved bubbling the glass melt at 1150°C in a Pt crucible with an SO2/O2/N2 gas mix to equilibrate the melt at a known pressure of SO3. Preliminary results suggested that performing one cycle of mixing and melting was not sufficient to saturate the glass. The bubbling method successfully incorporated sulfur into the glass but caused significant losses of sodium from the melt. In order to saturate the glass melt with sulfate without causing noticeable sodium loss, a modified crucible salt saturation method was developed by repeating the mixing and melting of the glass and salt mixture. For all three representative LAW glasses tested in this study, it was found that after three mixing and melting cycles, the sulfur concentration reaches a plateau, indicating reasonable sulfur saturation.

Jin, Tongan↗

Evaluation of the Microstructure and Property of TiNi SMA Prepared using VIM in BaZrO3 Crucible

The contamination from the crucible has been recognized as the main drawback of using vacuum induction melting (VIM) method to prepare TiNi shape memory alloys (SMAs). In the present work, we evaluated the feasibility of utilizing the highly-stable BaZrO3 crucible to prepare TiNi SMAs, whose microstructure and mechanical properties were investigated by High-energy X-ray Diffraction (HE-XRD), analytical Transmission Electron Microscopy (TEM), Differential Scanning Calorimetry (DSC) and tensile test. It was found that there were about 0.035 wt % oxygen and 0.039 wt % zirconium remained in the TiNi alloy after melting in BaZrO3 crucible, which fulfills the ASTM standard on biomedical TiNi alloys. Oxygen from the dissolution of BaZrO3 could form Ti4Ni2Ox phase, and zirconium exists as solute atoms in both of the matrix and second phase. After the thermomechanical processing and vacuum annealing at 850 degrees C, the alloy achieved 37.63% of fracture elongation and 880 MPa of tensile strength. The transformational strain and martensitic yield strain of the alloy reached about 8% and 21% respectively.

Gao, Pengyue↗

Directional solidification of silicon in carbon crucibles by an oscillating crucible technique

The quality of silicon cast by present techniques is limited by the presence of dislocations and grain boundaries in unseeded growth and by cellular structures with dislocation networks in the case of the seeded growth. To address these concerns, a new method of directional solidification called the oscillating crucible technique (OCT) is developed. During growth, a carbon crucible is oscillated to provide for effective stirring of the melt. This growth technique (seeded growth only), along with material characterization and solar-cell fabrication and testing, is described. Solar-cell efficiencies of up to 13 percent at 100 mW/sq cm area obtained in the single crystalline areas. Minority-carrier diffusion lengths exceeding 100 microns are measured even in the polycrystalline areas of the wafers. Limitations of the present setup and possible future improvements are discussed.

Daud, T.↗

Conversion of Nuclear Waste to Molten Glass: Cold-Cap Reactions in Crucible Tests

The feed-to-glass conversion, which comprises complex chemical reactions and phase transitions, occurs in the cold-cap zone during nuclear waste vitrification. Knowledge of the chemistry and physics of feed-to-glass conversion will help us control the conversion path by changing the melter feed makeup to maximize the glass production rate. To investigate the conversion process, we analyzed heat-treated samples of a simulated high-level waste feed using X-ray diffraction, electron probe microanalysis – wavelength dispersive X-ray spectroscopy, leaching tests, and residual anion analysis. Feed dehydration, gas evolution, and borate phase formation occurred at temperatures below 700 °C before the emerging glass-forming melt was completely connected. Above 800 °C, intermediate aluminosilicate phases and quartz particles were gradually dissolving in the continuous borosilicate melt, which expanded into transient foam. Knowledge of the chemistry and physics of feed-to-glass conversion will help us control the conversion path by changing the melter feed makeup to maximize the glass production rate.

Cold-cap↗

Covering a Crucible with Metal Containing Channels

In a procedure that partly resembles the lost-wax casting process, a crucible made of a brittle material (ceramic, quartz, or glass) is covered with a layer of metal containing channels. The metal cover and the channels can serve any or all of several purposes, depending upon the application: Typically, the metal would serve at least partly to reinforce the crucible. The channels could be used as passages for narrow objects that could include thermocouples and heat-transfer strips. Alternatively or in addition, channels could be used as flow paths for liquid or gaseous coolants and could be positioned and oriented for position- or direction-selective cooling. In some cases, the channels could be filled with known gases and sealed so that failure of the crucibles could be indicated by instruments that detect the gases. The process consists of three main steps. In the first step, a pattern defining the channels is formed by wrapping or depositing a material in the desired channel pattern on the outer surface of the crucible. The pattern material can be a plastic, wax, low-ash fibrous material, a soluble material, or other suitable material that can subsequently be removed easily. In a proof-of-concept demonstration (see figure), the crucible was an alumina cylinder and the mold material was plastic tie-down tape. In the second step, the patterned crucible is coated with metal. In one variation of the second step, a very thin layer containing or consisting of an electrically conductive material (e.g., gold, silver, or carbon) is painted or otherwise deposited on the mold-covered crucible, then the covering metal required for the specific application is electrodeposited on the very thin conducting layer. In another variation of the second step, the metal coat is formed by chemical vapor deposition. In the proof-of-concept demonstration, a layer of nickel 0.003 in. ( 0.08 mm) thick was electrodeposited. In the third step, the patterned material is removed. This is generally done by heating the crucible assembly until the patterned material melts and runs out, vaporizes, and/or decomposes to an ash, leaving the channels. Alternatively, if the patterned material is soluble, it can be removed by use of a suitable solvent. In the proof-of-concept demonstration, the tape was burned away by heating the assembly to a temperature of 600 C.

Grugel, Richard N.↗

Mutiple Czochralski growth of silicon crystals from a single crucible

An apparatus for the Czochralski growth of silicon crystals is presented which is capable of producing multiple ingots from a single crucible. The growth chamber features a refillable crucible with a water-cooled, vacuum-tight isolation valve located between the pull chamber and the growth furnace tank which allows the melt crucible to always be at vacuum or low argon pressure when retrieving crystal or introducing recharge polysilicon feed stock. The grower can thus be recharged to obtain 100 kg of silicon crystal ingots from one crucible, and may accommodate crucibles up to 35 cm in diameter. Evaluation of the impurity contents and I-V characteristics of solar cells fabricated from seven ingots grown from two crucibles reveals a small but consistent decrease in cell efficiency from 10.4% to 9.6% from the first to the fourth ingot made in a single run, which is explained by impurity build-up in the residual melt. The crystal grower thus may offer economic benefits through the extension of crucible lifetime and the reduction of furnace downtime.

Lane, R. L.↗

Crucible melt-out via monitoring thermal arrest

A limiting challenge of single crystal growth utilizing the Czochralski method is reusing crucibles after a growth because of the residual charge left in the crucible. It is shown that clean-out of residual charge from crucibles can be completed efficiently by monitoring thermal arrest during heating at a constant linear increase of power. This technique was demonstrated for removal of a range of oxide charges from iridium crucibles of varying sizes and for removal of copper charge from a graphite crucible. In conclusion, this simple and repeatable technique removes the need to use brute mechanical force, highly corrosive chemicals, or highly accurate temperature measurement to recover and reuse crucibles from crystal growths.

36 MATERIALS SCIENCE↗

State-of-the-art in Manufacturing Pyrochemical Processing Crucibles

Engineers at Los Alamos National Laboratory have been purifying plutonium through pyrochemical processing for many years. The harsh environments involved with the pyrochemical processes include high temperatures (700-900 °C), molten salts and reactive metals (MgCl 2 , PuCl 3 , NaCl-KCl, CaCl 2 , Pu, Ca), and chlorine gas. Because of these corrosive conditions, designing and developing the pyrochemical processing equipment has always been an intriguing technical challenge. In this article I focus on the design and development of the pyrochemical processing crucible for the electrorefining (ER) process, applying design for manufacturability principles throughout the process. I review the current crucible design and electrorefining process and explore possibilities of making the crucible as one part, building the anode and cathode into the crucible, and various material of construction improvements. Materials of construction that should be reviewed further include alumina, silicon nitride, and a tantalum carbon alloy. I briefly review the application of three-dimensional (3D) printing to the process of producing the ER crucible, including thermoplastic 3D printing and mechanical property concerns. I finish by summarizing current plans and possibilities of improving the ER crucible.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Compatibility of molten plutonium with wrought and additively manufactured metal crucibles

Understanding plutonium’s interaction with metals is crucial for optimizing pyrochemical operations, nuclear fuel containment, and various actinide processing techniques. Traditionally, tantalum crucibles are employed for plutonium processing due to their high durability, excellent temperature stability, and low solubility in plutonium. However, tantalum faces challenges such as plutonium wetting and diffusion, making surface coatings particularly important for crucibles in pyrochemical applications to enhance corrosion resistance against plutonium. Tantalum is also expensive and difficult to machine, prompting the need for advanced manufacturing techniques to address these challenges. Here, in this work, we investigate the interaction of Pu with tantalum and titanium crucibles fabricated using both traditional machining methods and laser powder bed fusion (LPBF) additive manufacturing (AM). LPBF-AM is an advanced technique that allows for the creation of complex geometries from traditionally difficult-to-machine metals by using a high-powered laser to build parts. Previous studies of conventional manufactured tantalum have utilized oxidation and carburization of the surface to mitigate plutonium wetting; however, no studies of surface modified LPBF-AM material have been undertaken. These studies are crucial, given the typical differences in the grain structure between conventional and LPBF-AM materials. All crucibles underwent differential scanning calorimetry to confirm the melting of plutonium. Subsequently, the crucibles were sectioned and mounted in epoxy for microstructural analysis using optical microscopy and scanning electron microscopy. This investigation, comparing the performance of wrought vs AM metal crucibles, provides a basis for future tooling applications in actinide processing techniques and can address the challenges associated with traditional machining, particularly in pyrochemical applications.

Actinides↗

Method of Fabricating Protective Coating for a Crucible with the Coating Having Channels Formed Therein

A method is provided for the fabrication of a protective coating for a crucible with channels being formed in the coating. A material is adhered to the outer wall of the crucible to form a pattern thereon. The outer wall of the crucible along with the pattern of material adhered thereto is next coated with another material. The material used to form the pattern should extend through the outer material coating to define at least one port therein. Next, the crucible with its pattern of material and outer coating material is heated to a temperature of transformation at which the pattern of material is transformed to a fluidic state while the crucible and outer coating material maintain their solid integrity. Such transformation could also be accomplished by using a solvent that causes the pattern of material to dissolve. Finally, the material in its fluidic state is removed via the at least one port formed in the outer material coating thereby leaving channels defined in the coating adjacent the outer wall of the crucible.

Richard N Grugel↗

Rotatable crucible for rapid solidification process

This invention relates to an apparatus for producing filament, fiber, ribbon or film from a molten material, comprising a preferably heat extracting crucible which contains a pool of molten material at a selected horizontal level in the pool. The crucible has an opening extending from above the free surface level to a bottom edge of the opening, the bottom edge being sufficiently below the free surface level so that the molten material cannot form and hold a meniscus by surface tension between the edge and the level of the free surface and further comprises a heat extracting substrate laterally disposed with respect to the crucible and which rotates about an axis of rotation. The substrate is positioned adjacent the edge of the opening which confines the molten material and prevents it from overflowing downwardly out of the crucible. The invention features rotating means which includes a first drive means for tiltably rotating the crucible about an axis of rotation which is coaxial with the axis of rotation of the substrate, so the crucible edge can be maintained a predetermined constant distance from the substrate. The distance chosen is suitable for depositing molten material on the substrate and the apparatus also has a second drive means which is drivingly connected to the substrate for continuously moving the surface of the substrate upwardly past the edge and a melt front formed at the interface of the molten material and the substrate surface.

Gaspar, Thomas↗

Quench Crucibles Reinforced with Metal

Improved crucibles consisting mainly of metal-reinforced ceramic ampules have been developed for use in experiments in which material specimens are heated in the crucibles to various high temperatures, then quenched by, for example, plunging the crucibles into water at room temperature. In a traditional quench crucible, the gap between the ampule and the metal cartridge impedes the transfer of heat to such a degree that the quench rate (the rate of cooling of the specimen) can be too low to produce the desired effect in the specimen. One can increase the quench rate by eliminating the metal cartridge to enable direct quenching of the ampule, but then the thermal shock of direct quenching causes cracking of the ampule. In a quench crucible of the present improved type, there is no gap and no metal cartridge in the traditional sense. Instead, there is an overlay of metal in direct contact with the ampule, as shown on the right side of the figure. Because there is no gap between the metal overlay and the ampule, the heat-transfer rate can be much greater than it is in a traditional quench crucible. The metal overlay also reinforces the ampule against cracking.

Holmes, Richard R.↗

Experience of Graphite Crucibles during the Pyrometallurgical Processing of Uranium

Throughout the history of processing molten uranium, various materials have been investigated and utilized for the containment of uranium at temperatures greater than 1135oC. Of these, graphite is the most prevalent material due to its ease of fabrication, expense, compatibility with induction systems, and robust characteristics. Graphite in contact with molten uranium will react to form uranium carbide species, thus a coating or mold is needed to prevent reaction of the uranium and the subsequent adherence of the solidified metal. During the pyrometallurgical treatment of used nuclear fuel for uranium recovery at the Idaho National Laboratory, two operational steps utilize graphite crucibles for containment of molten uranium. The cathode processor step separates molten salt from the uranium while the casting step blends uranium for de-enrichment and allows molten sampling of the uranium. Zirconia and yttria based materials on graphite are employed for the cathode processor and casting steps, respectively. For the cathode processor, zirconia coatings were applied initially to graphite crucibles but more recently a zirconia castable material has been molded into the graphite. Although not perfect, zirconia has been found to be compatible with both molten salt and uranium whereas yttria will react with molten salts if carried over to the casting operation. With development, the uranium losses associated with the reaction of uranium and zirconia have been reduced to approximately 1 wt. % of the total uranium throughput. Losses from yttria coating reaction during casting are typically an order of magnitude less than zirconia. The real benefit of these materials is their cost effectiveness given the multiple number of times the graphite crucibles can be reused and/or recoated. Nearly thirty uses have been recorded for graphite crucibles at both the cathode processor and casting operations. The amount of impurity pickup to the uranium products from the graphite crucibles has been minimal (<300 ppm) in terms of carbon, oxygen, zirconium, and yttrium content. Based on the promising results with the zirconia castable at the cathode processor, zirconia material has been cast into a graphite casting crucible and will be tested for comparison in the absence of salt.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Effects of crucible wetting during solidification of immiscible Pb-Zn

Many industrial uses for liquid phase miscibility gap alloys are proposed. However, the commercial production of these alloys into useful ingots with a reasonable amount of homogeneity is arduous because of their immiscibility in the liquid state. In the low-g environment of space gravitational settling forces are abated, thus solidification of an immiscible alloys with a uniform distribution of phases becomes feasible. Elimination of gravitational settling and coalescence processes in low-g also makes possible the study of other separation and coarsening mechanisms. Even with gravitational separation forces reduced, many low-g experiments have resulted in severely segregated structures. The segregation in many cases was due to preferential wetting of the crucible by one of the immiscible liquids. The objective was to analyze the wetting behavior of Pb-Zn alloys on various crucible materials in an effort to identify a crucible in which the fluid flow induced by preferential wetting is minimized. It is proposed that by choosing the crucible for a particular alloy so that the difference in surface energy between the solid and two liqud phases is minimized, the effects of preferential wetting can be diminished and possibly avoided. Qualitative experiments were conducted and have shown the competitive wetting behavior of the immiscible Pb-Zn system and 13 different crucible materials.

Degroh, Henry C., III↗

Effects of crucible wetting during solidification of immiscible Pb-Zn alloys

Many industrial uses for liquid phase miscibility gap alloys are proposed. However, the commercial production of these alloys into useful ingots with a reasonable amount of homogeneity is arduous because of their immiscibility in the liquid state. In the low-g environment of space gravitational settling forces are abated, thus solidification of an immiscible alloy with a uniform distribution of phases becomes feasible. Elimination of gravitational settling and coalescence processes in low-g also makes possible the study of other separation and coarsening mechanisms. Even with gravitational separation forces reduced, many low-g experiments have resulted in severely segregated structures. The segregation in many cases was due to preferential wetting of the crucible by one of the immiscible liquids. The objective was to analyze the wetting behavior of Pb-Zn alloys on various crucible materials in an effort to identify a crucible in which the fluid flow induced by preferential wetting is minimized. It is proposed that by choosing the crucible for a particular alloy so that the difference in surface energy between the solid and two liquid phases is minimized, the effects of preferential wetting can be diminished and possibly avoided. Qualitative experiments were conducted and have shown the competitive wetting behavior of the immiscible Pb-Zn system and 13 different crucible materials.

De Groh, H. C., III↗

Removal of Bifilms from Al Melts by Stirring in Unbaffled and Baffled Crucibles

The free surface of aluminum melt, during stirring under different rotation speeds in unbaffled and baffled crucibles, was simulated numerically using a RANS turbulence model coupled with a particle-tracking method. The effect of mechanical stirring of Al melts containing 0.3, 0.7, and 4.5 wt pct Mg in unbaffled and baffled crucibles on the rate of elimination of bifilms from the melt was also investigated using a reduced pressure test. The results showed that the stirring increased the rate of removal of bifilms from the melt due to an increase in the rate of formation of cracks on the bifilms. Using baffles in the crucible accelerated the rate of removal of bifilms by changing the pattern of movement of bifilms in the melt. The critical stirring speeds, above which the oxide layer on the Al melt could submerge into the bulk liquid, were determined by the simulation. It was confirmed by the experimental results to be about 158 and 420 RPM for the unbaffled and baffled crucibles, respectively.

36 MATERIALS SCIENCE↗

Influence of Crucible Materials on High-temperature Properties of Vacuum-melted Nickel-chromium-cobalt Alloy

A study of the effect of induction-vacuum-melting procedure on the high-temperature properties of a titanium-and-aluminum-hardened nickel-base alloy revealed that a major variable was the type of ceramic used as a crucible. Reactions between the melt and magnesia or zirconia crucibles apparently increased high-temperature properties by introducing small amounts of boron or zirconium into the melts. Heats melted in alumina crucibles had relatively low rupture life and ductility at 1,600 F and cracked during hot-working as a result of deriving no boron or zirconium from the crucible.

MATERIALS, PROPERTIES - STRESS-RUPTURE↗