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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.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Low-Cost Titanium Casting Technology

This is the final report of "Low-Cost Titanium Casting Technology" project. Titanium alloys have attracted increasing attentions as structural materials for high performance and weight-sensitive applications in aerospace and biomedical fields. However, in mass-production of civil applications like automotive components, titanium alloys are scarcely used due to the unaffordable costs in manufacturing compared with other metallic materials, such as aluminum, magnesium and steel. Therefore, there is a need to reduce the manufacturing cost of titanium alloys so that titanium alloys can be more competitive in terms of property and cost considerations. In this 4-year project, we started from exploring new low-cost titanium alloy systems with the guidance of Integrated Computational Materials Engineering – Calculation of Phase Diagram (ICME-CALPHAD) framework, and determined several promising alloy systems, alloying elements including Ti-Al-Fe-Mn-B-C, that can allow further development (lab-scale and industry-scale) in the future. During the new alloy system exploration, considerable amount of scientific work was completed regarding CALPHAD modeling, microstructure morphology, mechanical properties, and processing of the new alloy systems. The relevant ternary titanium alloy systems, Ti-Al-Mn and Ti-Al-Fe, were examined and reassessed both computationally and experimentally, leading to more comprehensive understanding of these alloy systems. Based on this above study, a new low-cost casting titanium alloy was developed, Ti-6Al-5Fe-0.05B-0.05C (designated as T65-0.05BC), which has competitive as-cast strength level with current commercial titanium alloys but relatively low ductility. However, in this project, since the target application, automotive engine connecting rod, is a fatigue-limited component and does not require high ductility, this alloy shall suffice as the deliverable alloy in this project. After designing and confirming the potent of the new alloy, we designed and built a lab-scale manufacturing equipment aided by computational tools at OSU labs to conceptually prove that this alloy can be manufactured with permanent mold casting, which is low-cost and potentially a mass production process. We produced a lab-scale prototype connecting rod demonstrating the capability of permanent mold casting of this new alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Center For Actinide Science and Technology (CAST)

CAST encompassed 17 senior researchers in its first funding cycle and added two additional theorists briefly in the final two years. Approximately 37 graduate students and post-doctoral associates were supported by CAST. Within the 19 senior researchers there were changes in composition since the center was first funded. One researcher left associated with a move to another university. Two were phased out because they did not meet the expectations of CAST in terms of research performance. These decisions were always made in consultation with our External Advisory Committee (EAC) and DOE management. In fact, the phasing out of the two PI’s was suggested first by the EAC. Two new researchers were also brought in response to feedback at our midterm review where it was suggested that we needed increased theory support in CAST. No further changes were implemented since then, and CAST researchers thought that stability and optimal productivity was achieved.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Tape casting and characterizations of MgO ceramics

Herein we report a high density MgO ceramic substrate produced by the tape casting technology. The tape casting formulation and process produced a uniform tape free of cracking. Y 2 O 3 and SiO 2 were used as the sintering aid for the pressureless sintering of the green tape. X-ray diffraction phase identification indicates that MgO is the main phase, while both Y 2 O 3 and SiO 2 sintering aids react with MgO to form MgY 4 Si 3 O 13 as the second phase. Liquid phase sintering occurs in the temperature range from 1030°C to ~1500°C, which is confirmed by the simultaneous Thermal Gravitation Analysis/ Differential Scanning Calorimeter (TGA/DSC) and the percent linear shrinkage and densification. A 96.5% theoretical density was achieved by presureless sintering at 1650°C for 2 hours, which was further increased to a fully dense structure using hotisostatic- pressing(HIP) at 1650°C and 207 MPa in argon. Scanning electron microscopy (SEM) and energy dispersive(EDS) spectroscopic analysis on the HIP’ed sample show that MgY 4 Si 3 O 13 is located at the MgO grain boundary and the sample has a fully dense structure. The refractive indices and extinction coefficient were measured on the HIP’ed sample along with thermal properties and dielectric properties. Thermal diffusivity and heat capacity were measured to calculate the thermal conductivity.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Advanced Characterization of Microwave Melt Cast Uranium

For the last decade, the use of microwave (MW) melting and casting technology for processing uranium (U) has been under development at Y-12 National Security Complex in Oak Ridge, TN [2] . Their objective has been to determine if MW is a viable option to replace conventional vacuum induction melting (VIM) for some U part types. Some of the benefits of using MW technology are minimizing processing steps and decreasing impurity content by changing crucible material, which will help to lower costs and improve machinability, respectively. While Y-12 has shown success using a MW melting and casting process to make U parts [4, 5], it is still a relatively new technology for casting metals, and there are several unknowns with respect to how the material properties compare to conventional VIM cast U. One major concern, associated with MW casting of metals, is superheating, which can cause arcing or plasma formation in a part and result in non-uniform material properties. Therefore, studying the anisotropy in MW cast metals in terms of pertinent properties is highly relevant. Specifically, the properties of interest here are deformation behavior and mechanical properties of U tested at different strain rates and weldability of thin wall sections. In order to address concerns about high strain rate mechanical properties, prototype MW-U parts (processed in 2009) were sent to LLNL in 2015 for advanced materials testing. The parts received had relatively thin walls (~6 mm), so Split Hopkinson Pressure Bar was selected as a method for dynamic mechanical testing (strain rate of ~103s-1) since most other high-rate (HR) tests require much larger sample dimensions. A VIM-U part from Y-12 was not available at the time of the study, so a VIM part from Idaho National Laboratory, cast into a rectangular block, was used here for comparison.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Feasibility Study of Continuous Casting of Steel Billets in Twin-Belt Caster

Integrated casting and rolling in a series production line is well established for the non-ferrous metals through the use of twin-belt casting technology. However, this twin-belt casting with high mass flow is not yet commercialized in the continuous production of steel alloys. A novel steel casting for the in-line rolling (named LUUP method) is presented and one main focus of this work is to design a casting machine: twin-belt caster. Influence of mass flow rate and dimensional ratio on the solidification, compensation, and total process length is addressed. A gap-dependent belt and dam block side heat transfer is modeled. The admissible casting speed due to the limitations of caster length and shell strength is addressed. The total process length only depends on the mass flow rate. A 2D traveling slice numerical model is presented with realistic boundary conditions for the entire process starting from the meniscus to roll mill entry.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Casting Aluminum Alloys: Their Physical and Mechanical Metallurgy

The follow up to the fall 2007 work on the structure, properties, thermal resistance, corrosion and fatigue of aluminum alloys in industrial manufacturing, discusses findings from the past decade, including sections on new casting alloys, novel casting technologies, and new methods of alloys design. The book also includes other hot topics, such as the implementation of computational technologies for the calculation of phase equilibria and thermodynamic properties of alloys, the development of software for calculation of diffusion processes in aluminum alloys, computational modeling of solidification microstructure and texture evolution of multi-component aluminum materials.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Manufacturing and Characterization of Ultra Pure Ferrous Alloys Final Report CRADA No. TC02069.0

This CRADA was a.collaborative effort between the Lawrence Livermore National Security LLC (formerly University of California)/Lawrence Livermore National Laboratory (LLNL),and Caterpillar Inc. (CaterpiHar), to further advance levitation casting techniques (developed at the Central Research Institute for Material (CRIM) in St. Petersburg, Russia) for use in manufacturing high purity metal alloys. This DOE Global Initiatives for Proliferation Prevention Program (IPP) project was to develop and demonstrate the levitation casting technology for producing ultra-pure alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Progress and Technology Assessment of Melt-Cast Ceramic Waste Forms

The Savannah River National Laboratory (SRNL) conducted research from FY2011 – FY2020 to develop ceramic waste forms to treat High-Level Waste (HLW) resulting from reprocessing of commercial Used Nuclear Fuel (UNF) as part of the Department of Energy (DOE) office of Nuclear Energy (NE) Fuel Cycle Technologies (FCT) research program. The objective of the research was to develop a reference ceramic waste form and process technology needed to immobilize the combined HLW raffinate stream, including undissolved solids and soluble technetium, and potentially the TRU waste stream resulting from reprocessing processes. This report compiles the relevant literature produced under, and pertinent to, the program objectives and provides a perspective on the technology development as well as prospects for future.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

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↗
DOE OSTI2018

Microstructure and Electrical Transport Properties of Bi{sub 3}TiNbO{sub 9} High-Temperature Piezoceramics

High-density ceramic samples of the Bi{sub 3}TiNbO{sub 9} ferroelectric phase with a layered perovskite-like structure have been produced by tape casting slurry technology and hot pressing processes. The samples have been characterized by X-ray diffraction and dielectric, piezoelectric, and pyroelectric measurements. The results demonstrate that the samples have a well-defined texture due to the preferential orientation of the basal planes of their platelike grains across the pressing axis or along the film casting direction. The Curie temperature of the samples has been determined to be T{sub C} = 1180 K. The samples have anisotropic electrical transport characteristics. Their piezoelectric constants d{sub 33} in directions perpendicular and parallel to the texture plane is 22 and 5 pC/N, respectively. The conclusion has been drawn that the synthesized materials are potentially attractive for producing high-temperature piezoelectric elements.

36 MATERIALS SCIENCE↗
DOE OSTI2021

From casting to 3D printing geopolymers: A proof of concept

The objective of this paper is to define a mix design strategy allowing the implementation of geopolymer in powder bed 3D printing. In a selective binder approach, an aluminosilicate powder bed is activated through the deposit of an alkaline silicate solution. We first show that, in comparison to casting, this technology requires mastering the spreading of the liquid into the powder bed to ensure that the reaction takes place where it is needed. A series of experiments at the drop level, mimicking the 3D printing process, were performed to determine the printing solution composition for a given powder bed packing. We then highlight the relationship between the compressive strength of the printed geopolymer and the powder bed saturation, controlled by the printing parameters. Finally, SEM/EDX analysis confirm the formation of geopolymer with desired Si/Al and Na/Al ratios in the resulting printed material.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Manufacture of Wear-Resistant Cast-Iron Grinding Balls without Shrinkage Defects

A manufacturing technology has been developed for wear-resistant cast-iron grinding balls without shrinkage defects. In this method, the balls are cast in single-use sand–clay molds. A new approach to designing the casting system is developed. By numerical modeling, the time dependence of solidification is derived. As a trial, grinding balls are produced by the proposed technology.

42 ENGINEERING↗
DOE OSTI2019

Effects of Transition Layer on Bending Resistance in Copper-Clad Aluminum Composite Casting

The performance of the transition layer in a Cu/Al composite casting directly affects the quality of subsequent plastic deformation processing; however, there are no universal or standardized measurement indices for the performance of the transition layer. In this study, Cu/Al composite castings were prepared using the pouring aluminum method, and the resulting solidification microstructures on the bending resistance were investigated. The results of this study lay a theoretical foundation for the development of the plastic processing technologies of these composite castings. A thinner transition layer in the Cu/Al composite casting led to improved bending resistance. In addition, for a fixed total thickness of the transition layer, the bending resistance was mainly controlled by the γ/β interface and β + eutectic (α + β) microstructure, and the thickness of the γ phase had a negligible effect on the bending resistance. The γ/β interface cracked first when the transition layer bore the tensile and shear stress during the bending process, which resulted in the transition layer easily separating from the copper. The bending resistance of the transition layer can be feasibly judged by measuring the bending angle of the specimen tip, which can be easily performed when the specimen bends toward the aluminum direction, suggesting that our proposed method has considerable practical significance.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Study of Ferrite During Refinement of Prior Austenite Grains in Microalloyed Steel Continuous Casting

The formation of coarse prior austenite grain is a key factor to promote transverse crack, and the susceptibility to the transverse crack can be reduced by refining the austenite grain size. In the present study, the high-temperature confocal laser scanning microscope (CLSM) was used to simulate two types of double phase-transformation technologies. The distribution and morphology of ferrites under different cooling conditions were analyzed, and the effects of ferrite distribution and morphology on the double phase-transformation technologies were explored to obtain the suitable double phase-change technology for the continuous casting process. The results indicate that, under the thermal cycle TH0 [the specimens were cooled down to 913 K (640 °C) at a cooling rate of 5.0 K/s (5.0 °C/s)], the width of prior austenite grain boundaries was thick, and the dislocation density at grain boundaries was high. It had strong inhibition effect on crack propagation; under the thermal cycle TH1 [the specimens were cooled down to 1073 K (800 °C) at a cooling rate of 5.0 K/s (5.0 °C/s) and then to 913 K (640 °C) at a cooling rate of 1.0 K/s (1.0 °C/s)], the width of prior austenite grain boundary was thin, and the dislocation density at grain boundaries was low. It was beneficial to crack propagation. After the first phase change, the developed film-like ferrite along the austenite grain boundaries improved the nucleation conditions of new austenitic grains and removed the inhibition effect of the prior austenite grain boundaries on the austenite grain size.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Abstract for CRADA between the National Energy Technology Laboratory and General Motors (AGMT-0876)

Lightweight aluminum shape castings have widespread applications for structural components in the automotive, aerospace, and general engineering industries because of their excellent castability, corrosion resistance, and particularly high strength-to-weight ratio in the heat-treated condition. In the automotive industry, cast aluminum alloys have been increasingly used to replace cast iron and steel in vehicle applications such as engine blocks, cylinder heads, intake manifolds, brackets, housings, chassis, transmission parts, and suspension systems to reduce mass. As many of the aluminum shape castings used in automobiles involve cyclic loading, fatigue properties of the castings are critical to their success. The increasing use of lightweight aluminum cast components in critical structures thus requires improved integrity, with more reliable and quantifiable performance. The objective of this project is to demonstrate and further develop GM’s patent-pending, novel casting process, “Pressure-Assistant Precision Sand Casting (PAPSC) for producing flawless cast aluminum cylinder heads with minimum manufacturing and energy costs”. The approach is to leverage NETL’s experience in producing high-quality metal castings through various microstructure control and defect elimination technologies as well as comprehensive quantification of microstructure characteristics and mechanical properties. A baseline (production) alloy together with the melt treatment will be initially evaluated with the new PAPSC process to develop and validate the process window for producing flawless cast aluminum heads.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimization of Tape Casting for Fabrication of Li 6.25 Al 0.25 La 3 Zr 2 O 12 Sheets

Tape casting is an attractive technology for the scalable manufacturing of thin lithium garnet electrolyte (LLZO) layers for solid state battery applications. Processing of LLZO is complicated by many factors including lithium volatilization, abnormal grain growth, and phase instability, which are exacerbated by high surface area to volume ratios. In this work a sintering protocol for commercially available Li 6.25 Al 0.25 La 3 Zr 2 O 12 Sheets (Al-LLZO) powder was developed that requires no mother-powder covering or externally applied pressure. MgO was investigated as a sintering additive to improve density and ionic conductivity of the Al-LLZO sheets and produce a fine-grained microstructure. Al-LLZO sheets with 5 wt % MgO had densities of > 90% and ionic conductivity > 2 × 10 -4 S/cm. The optimized ceramic composition and sintering protocol were used to compare several tape casting binder systems. A "green"water-based system using methylcellulose as a binder was developed with green and final properties comparable to those obtained with solvent-based systems.

25 ENERGY STORAGE↗
DOE OSTI2016

High-Resolution Characterization of UMo Alloy Microstructure

This report highlights the capabilities and procedure for high-resolution characterization of UMo fuels in PNNL. Uranium-molybdenum (UMo) fuel processing steps, from casting to forming final fuel, directly affect the microstructure of the fuel, which in turn dictates the in-reactor performance of the fuel under irradiation. In order to understand the influence of processing on UMo microstructure, microstructure characterization techniques are necessary. Higher-resolution characterization techniques like transmission electron microscopy (TEM) and atom probe tomography (APT) are needed to interrogate the details of the microstructure. The findings from TEM and APT are also directly beneficial for developing predictive multiscale modeling tools that can predict the microstructure as a function of process parameters. This report provides background on focused-ion-beam–based TEM and APT sample preparation, TEM and APT analysis procedures, and the unique information achievable through such advanced characterization capabilities for UMo fuels, from a fuel fabrication capability viewpoint.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗