National Library of Energy BETA

Sample records for foam metal casting

  1. Manufacturers Saving with Lost Foam Metal Casting | Department...

    Energy Savers [EERE]

    Metal casting was identified as one of the top 10 energy users in manufacturing. The technology represents a 20- to 25-percent reduction in production costs and uses 7 percent...

  2. LOST FOAM CASTING OF MAGNESIUM ALLOYS

    SciTech Connect (OSTI)

    Han, Qingyou [ORNL; Dinwiddie, Ralph Barton [ORNL; Sklad, Philip S [ORNL; Currie, Kenneth [Tennessee Technological University; Abdelrahman, Mohamed [Tennessee Technological University; Vondra, Fred [Tennessee Technological University; Walford, Graham [Walford Technologies; Nolan, Dennis J [Foseco-Morval

    2007-01-01

    The lost foam casting process has been successfully used for making aluminum and cast iron thin walled castings of complex geometries. Little work has been carried out on cast magnesium alloys using the lost foam process. The article describes the research activities at Oak Ridge National Laboratory and Tennessee Technological University on lost foam casting of magnesium alloys. The work was focused on castings of simple geometries such as plate castings and window castings. The plate castings were designed to investigate the mold filling characteristics of magnesium and aluminum alloys using an infrared camera. The pate castings were then characterized for porosity distribution. The window castings were made to test the castability of the alloys under lost foam conditions. Significant differences between lost foam aluminum casting and lost foam magnesium casting have been observed.

  3. Manufacturing Advanced Engineered Components Using Lost Foam Casting Technology

    SciTech Connect (OSTI)

    None

    2004-11-01

    The project will further reduce porosity and fold defects in lost foam casting to improve production efficiency, mechanical properties, and marketability of castings.

  4. Improvement of the Lost Foam Casting Process

    Broader source: Energy.gov [DOE]

    Casting is an energy-intensive manufacturing process within the metal casting and aluminum industries, requiring natural gas to melt aluminum and electricity to run equipment. The higher-than...

  5. Advanced lost foam from casting technology

    SciTech Connect (OSTI)

    Bates, C. E.; Littleton, H. E.; Askeland, D.; Griffin, J.; Miller, B. A.; Sheldon, D. S.

    1996-05-01

    Previous research made significant advances in understanding the Lost Foam Casting (LFC) Process and clearly identified areas where additional research was needed to improve the process and make it more functional in an industrial environment. The current project focused on five areas listed as follows: Task 1: Precision Pattern Production Task 2: Pattern Coating Consistency Task 3: Sand Fill and Compaction Effects Task 4: Pattern Gating Task 5: Mechanical Properties of Castings. This report summarizes the work done under the current contract in all five areas in the period of October 1, 1994 through December 31, 1995. Twenty-eight (28) companies jointly participate in the project. These companies represent a variety of disciplines, including pattern designers, pattern producers, coating manufacturers, plant design companies, compaction equipment manufacturers, casting producers, and casting buyers.

  6. Comparison of Lost Foam Casting of AM60B Alloy and A356 Alloy

    SciTech Connect (OSTI)

    Han, Qingyou [ORNL; Dinwiddie, Ralph Barton [ORNL; Sklad, Philip S [ORNL; Currie, Kenneth [Tennessee Technological University; Vondra, Fred [Tennessee Technological University; Abdelrahman, Mohamed [Tennessee Technological University; Walford, Graham [Walford Technologies; Nolan, Dennis J [Foseco-Morval; Nedkova, Teodora [Kaiser Aluminum

    2007-01-01

    The article describes the research activities at Oak Ridge National Laboratory and Tennessee Technological University on lost foam casting of magnesium alloys. The work was focused on castings of simple geometries such as plate castings and window castings in order to compare the difference in castability between magnesium alloys and aluminum alloy using the lost foam casting process. Significant differences between lost foam aluminum casting and lost foam magnesium casting have been observed.

  7. Advanced Lost Foam Casting Technology - Phase V

    SciTech Connect (OSTI)

    Wanliang Sun; Harry E. Littleton; Charles E. Bates

    2004-04-29

    Previous research, conducted under DOE Contracts DE-FC07-89ID12869, DE-FC07-93ID12230 and DE-FC07-95ID113358 made significant advances in understanding the Lost Foam Casting (LFC) Process and clearly identified areas where additional developments were needed to improve the process and make it more functional in industrial environments. The current project focused on eight tasks listed as follows: Task 1--Computational Model for the Process and Data Base to Support the Model; Task 2--Casting Dimensional Accuracy; Task 3--Pattern Production; Task 4--Improved Pattern Materials; Task 5--Coating Control; Task 6--In-Plant Case Studies; Task 7--Energy and the Environmental Data; and Task 8--Technology Transfer. This report summarizes the work done on all tasks in the period of October 1, 1999 through September 30, 2004. The results obtained in each task and subtask are summarized in this Executive Summary and details are provided in subsequent sections of the report.

  8. Clean Metal Casting

    SciTech Connect (OSTI)

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

    The objective of this project is to develop a technology for clean metal processing that is capable of consistently providing a metal cleanliness level that is fit for a given application. The program has five tasks: Development of melt cleanliness assessment technology, development of melt contamination avoidance technology, development of high temperature phase separation technology, establishment of a correlation between the level of melt cleanliness and as cast mechanical properties, and transfer of technology to the industrial sector. Within the context of the first task, WPI has developed a standardized Reduced Pressure Test that has been endorsed by AFS as a recommended practice. In addition, within the context of task1, WPI has developed a melt cleanliness sensor based on the principles of electromagnetic separation. An industrial partner is commercializing the sensor. Within the context of the second task, WPI has developed environmentally friendly fluxes that do not contain fluorine. Within the context of the third task, WPI modeled the process of rotary degassing and verified the model predictions with experimental data. This model may be used to optimize the performance of industrial rotary degassers. Within the context of the fourth task, WPI has correlated the level of melt cleanliness at various foundries, including a sand casting foundry, a permanent mold casting foundry, and a die casting foundry, to the casting process and the resultant mechanical properties. This is useful in tailoring the melt cleansing operations at foundries to the particular casting process and the desired properties of cast components.

  9. Method of casting pitch based foam

    DOE Patents [OSTI]

    Klett, James W. (Knoxville, TN)

    2002-01-01

    A process for producing molded pitch based foam is disclosed which minimizes cracking. The process includes forming a viscous pitch foam in a container, and then transferring the viscous pitch foam from the container into a mold. The viscous pitch foam in the mold is hardened to provide a carbon foam having a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts.

  10. Nanostructured metal foams: synthesis and applications

    SciTech Connect (OSTI)

    Luther, Erik P; Tappan, Bryce; Mueller, Alex; Mihaila, Bogdan; Volz, Heather; Cardenas, Andreas; Papin, Pallas; Veauthier, Jackie; Stan, Marius

    2009-01-01

    Fabrication of monolithic metallic nanoporous materials is difficult using conventional methodology. Here they report a relatively simple method of synthesizing monolithic, ultralow density, nanostructured metal foams utilizing self-propagating combustion synthesis of novel metal complexes containing high nitrogen energetic ligands. Nanostructured metal foams are formed in a post flame-front dynamic assembly with densities as low as 0.011 g/cc and surface areas as high as 270 m{sup 2}/g. They have produced metal foams via this method of titanium, iron, cobalt, nickel, zirconium, copper, palladium, silver, hafnium, platinum and gold. Microstructural features vary as a function of composition and process parameters. Applications for the metal foams are discussed including hydrogen absorption in palladium foams. A model for the sorption kinetics of hydrogen in the foams is presented.

  11. Advanced lost foam casting technology. 1995 summary report

    SciTech Connect (OSTI)

    Bates, C.E.; Littleton, H.E.; Askeland, D.; Griffin, J.; Miller, B.A.; Sheldon, D.S.

    1996-05-01

    Previous research made significant advances in understanding the Lost Foam Casting (LFC) Process and clearly identified areas where additional research was needed to improve the process and make it more functional in an industrial environment. The current project focused on five areas listed as follows: Task 1: Precision Pattern Production; Task 2: Pattern Coating Consistency; Task 3: Sand Fill and Compaction Effects; Task 4: Pattern Gating; and Task 5: Mechanical Properties of Castings. This report summarizes the work done under the current contract in all five areas. Twenty-eight (28) companies jointly participate in the project. These companies represent a variety of disciplines, including pattern designers, pattern producers, coating manufacturers, plant design companies, compaction equipment manufacturers, casting producers, and casting buyers. This report summarizes the work done in the past two years and the conclusions drawn from the work.

  12. Advanced Lost Foam Casting technology: 1997 summary report

    SciTech Connect (OSTI)

    1997-12-31

    Previous research made significant advances in understanding the Lost Foam Casting (LFC) Process and clearly identified areas where additional research was needed to improve the process and make it more functional in an industrial environment. The current project focused on eight tasks listed as follows: Task 1--pyrolysis defects and sand distortion; Task 2--bronze casting technology; Task 3--steel casting technology; Task 4--sand filling and compaction; Task 5--coating technology; Task 6--precision pattern production; Task 7--computational modeling; and Task 8--project management and technology transfer. This report summarizes the work done under the current contract in all eight tasks in the period of October 1, 1995 through December 31, 1997.

  13. ITP Metal Casting: A Vision for the U.S. Metal Casting Industry...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    A Vision for the U.S. Metal Casting Industry: 2002 and Beyond ITP Metal Casting: A Vision for the U.S. Metal Casting Industry: 2002 and Beyond mcvision.pdf More Documents &...

  14. Low density metal hydride foams

    DOE Patents [OSTI]

    Maienschein, Jon L. (Oakland, CA); Barry, Patrick E. (Pleasant Hill, CA)

    1991-01-01

    Disclosed is a low density foam having a porosity of from 0 to 98% and a density less than about 0.67 gm/cc, prepared by heating a mixture of powered lithium hydride and beryllium hydride in an inert atmosphere at a temperature ranging from about 455 to about 490 K for a period of time sufficient to cause foaming of said mixture, and cooling the foam thus produced. Also disclosed is the process of making the foam.

  15. Final Technical Report Quantification and Standardization of Pattern Properties for the Control of the Lost Foam Casting Process

    SciTech Connect (OSTI)

    Ronald Michaels

    2005-09-30

    This project takes a fresh look at the ''white side'' of the lost foam casting process. We have developed the gel front hypothesis for foam pyrolysis behavior and the magnetic metal pump method for controlling lost foam casting metal fill event. The subject of this report is work done in the improvement of the Lost Foam Casting Process. The original objective of this project was to improve the control of metal fill by understanding the influence of foam pattern and coating properties on the metal fill event. Relevant pattern properties could then be controlled, providing control of the metal fill event. One of the original premises of this project was that the process of metal fill was relatively well understood. Considerable previous work had been done to develop fluid mechanical and heat transfer models of the process. If we could just incorporate measured pattern properties into these models we would be able predict accurately the metal fill event. As we began to study the pyrolysis behavior of EPS during the metal fill event, we discovered that the chemical nature of this event had been completely overlooked in previous research. Styrene is the most prevalent breakdown product of EPS pyrolysis and it is a solvent for polystyrene. Much of the styrene generated by foam pyrolysis diffuses into intact foam, producing a molten gel of mechanically entangled polystyrene molecules. Much of the work of our project has centered on validation of this concept and producing a qualitative model of the behavior of EPS foam undergoing pyrolysis in a confined environment. A conclusion of this report is that styrene dissolution in EPS is a key phenomenon in the pyrolysis process and deserves considerable further study. While it is possible to continue to model the metal fill event parametrically using empirical data, we recommend that work be undertaken by qualified researchers to directly characterize and quantify this phenomenon for the benefit of modelers, researchers, and workers in the field. Another original premise of this project was that foam pattern and coating properties could be used to efficiently control metal fill. After studying the structure of EPS foam in detail for the period of this contract, we have come to the conclusion that EPS foam has an inherent variability at a scale that influences metal fill behavior. This does not allow for the detailed fine control of the process that we originally envisioned. We therefore have sought other methods for the control of the metal fill event. Of those, we now believe that the magnetic metal pump shows the most promise. We have conducted two casting trials using this method and preliminary results are very encouraging. A conclusion of our report is that, while every effort should continue to be made to produce uniform foam and coatings, the use of the magnetic metal pump should be encouraged and closed loop control mechanisms should be developed for this pouring method.

  16. Energy Saving Melting and Revert Reduction Technology (Energy SMARRT): Manufacturing Advanced Engineered Components Using Lost Foam Casting Technology

    SciTech Connect (OSTI)

    Harry Littleton; John Griffin

    2011-07-31

    This project was a subtask of Energy Saving Melting and Revert Reduction Technology (�¢����Energy SMARRT�¢���) Program. Through this project, technologies, such as computer modeling, pattern quality control, casting quality control and marketing tools, were developed to advance the Lost Foam Casting process application and provide greater energy savings. These technologies have improved (1) production efficiency, (2) mechanical properties, and (3) marketability of lost foam castings. All three reduce energy consumption in the metals casting industry. This report summarizes the work done on all tasks in the period of January 1, 2004 through June 30, 2011. Current (2011) annual energy saving estimates based on commercial introduction in 2011 and a market penetration of 97% by 2020 is 5.02 trillion BTU�¢����s/year and 6.46 trillion BTU�¢����s/year with 100% market penetration by 2023. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology. The average annual estimate of CO2 reduction per year through 2020 is 0.03 Million Metric Tons of Carbon Equivalent (MM TCE).

  17. ITP Metal Casting: Energy and Environmental Profile of the U...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    and Environmental Profile of the U.S. Metal casting Industry ITP Metal Casting: Energy and Environmental Profile of the U.S. Metal casting Industry profile.pdf More Documents &...

  18. ITP Metal Casting: Advanced Melting Technologies: Energy Saving...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Advanced Melting Technologies: Energy Saving Concepts and Opportunities for the Metal Casting Industry ITP Metal Casting: Advanced Melting Technologies: Energy Saving Concepts and...

  19. Reliability Tools for Resonance Inspection of Light Metal Castings...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Tools for Resonance Inspection of Light Metal Castings Reliability Tools for Resonance Inspection of Light Metal Castings 2012 DOE Hydrogen and Fuel Cells Program and Vehicle...

  20. THE CHOICE OF THE PROPER REFRACTORY FOR THE CASTING OF HIGH MELTING ELECTROPOSITIVE METALS

    E-Print Network [OSTI]

    Brewer, Leo

    2008-01-01

    for the Casting of High Melting Electropositive Metals Leothe Casting of High Melting Electropositive Metals" (Report

  1. Manufacturers Saving with Lost Foam Metal Casting

    Office of Energy Efficiency and Renewable Energy (EERE)

    The technology represents a 20- to 25-percent reduction in production costs and uses 7 percent fewer materials than traditional processes.

  2. Light Metals Permanent Mold Casting

    SciTech Connect (OSTI)

    None

    2004-11-01

    The research will develop the gravity and/or low-pressure permanent-mold casting processes with sand or permanent-mold cores for aluminum and magnesium based alloys.

  3. Casting Loop Quantum Cosmology in the Spin Foam Paradigm

    E-Print Network [OSTI]

    Abhay Ashtekar; Miguel Campiglia; Adam Henderson

    2010-04-03

    The goal of spin foam models is to provide a viable path integral formulation of quantum gravity. Because of background independence, their underlying framework has certain novel features that are not shared by path integral formulations of familiar field theories in Minkowski space. As a simple viability test, these features were recently examined through the lens of loop quantum cosmology (LQC). Results of that analysis, reported in a brief communication [1], turned out to provide concrete arguments in support of the spin foam paradigm. We now present detailed proofs of those results. Since the quantum theory of LQC models is well understood, this analysis also serves to shed new light on some long standing issues in the spin foam and group field theory literature. In particular, it suggests an intriguing possibility for addressing the question of why the cosmological constant is positive and small.

  4. Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Lost Foam Thin Wall - Feasibility of Producing Lost Foam Castings in Aluminum and Magnesium Based Alloys

    SciTech Connect (OSTI)

    Fasoyinu, Yemi; Griffin, John A.

    2014-03-31

    With the increased emphasis on vehicle weight reduction, production of near-net shape components by lost foam casting will make significant inroad into the next-generation of engineering component designs. The lost foam casting process is a cost effective method for producing complex castings using an expandable polystyrene pattern and un-bonded sand. The use of un-bonded molding media in the lost foam process will impose less constraint on the solidifying casting, making hot tearing less prevalent. This is especially true in Al-Mg and Al-Cu alloy systems that are prone to hot tearing when poured in rigid molds partially due to their long freezing range. Some of the unique advantages of using the lost foam casting process are closer dimensional tolerance, higher casting yield, and the elimination of sand cores and binders. Most of the aluminum alloys poured using the lost foam process are based on the Al-Si system. Very limited research work has been performed with Al-Mg and Al-Cu type alloys. With the increased emphasis on vehicle weight reduction, and given the high-strength-to-weight-ratio of magnesium, significant weight savings can be achieved by casting thin-wall (? 3 mm) engineering components from both aluminum- and magnesium-base alloys.

  5. Horizontal electromagnetic casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, John R. (Hinsdale, IL); Lari, Robert J. (Aurora, IL); Praeg, Walter F. (Palos Park, IL); Turner, Larry R. (Naperville, IL)

    1988-01-01

    Thin metal sheets are cast by magnetically suspending molten metal deposited within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled to form a solid metal sheet. Magnetic flux increases as the molten metal sheet moves downward and decreases as the molten metal sheet moves upward to stabilize the sheet and maintain it in equilibrium as it is linearly displaced and solidified by cooling gases. A conducting shield is electrically coupled to the molten metal sheet by means of either metal sheet engaging rollers or brushes on the solidified metal, and by means of an electrode in the vessel containing the molten metal thereby providing a return path for the eddy currents induced in the metal sheet by the AC coil generated magnetic flux. Variation in the geometry of the conducting shield allows the magnetic flux between the metal sheet and the conducting shield to be varied and the thickness in surface quality of the metal sheet to be controlled. Side guards provide lateral containment for the molten metal sheet and stabilize and shape the magnetic field while a leader sheet having electromagnetic characteristics similar to those of the metal sheet is used to start the casting process and precedes the molten metal sheet through the magnet and forms a continuous sheet therewith. The magnet may be either U-shaped with a single racetrack coil or may be rectangular with a pair of facing bedstead coils.

  6. Horizontal electromagnetic casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, John R. (Hinsdale, IL); Lari, Robert J. (Aurora, IL); Praeg, Walter F. (Palos Park, IL); Turner, Larry R. (Naperville, IL)

    1987-01-01

    Thin metal sheets are cast by magnetically suspending molten metal deposited within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled to form a solid metal sheet. Magnetic flux increases as the molten metal sheet moves downward and decreases as the molten metal sheet moves upward to stabilize the sheet and maintain it in equilibrium as it is linearly displaced and solidified by cooling gases. A conducting shield is electrically coupled to the molten metal sheet by means of either metal sheet engaging rollers or brushes on the solidified metal, and by means of an electrode in the vessel containing the molten metal thereby providing a return path for the eddy currents induced in the metal sheet by the AC coil generated magnetic flux. Variation in the geometry of the conducting shield allows the magnetic flux between the metal sheet and the conducting shield to be varied and the thickness in surface quality of the metal sheet to be controlled. Side guards provide lateral containment for the molten metal sheet and stabilize and shape the magnetic field while a leader sheet having electromagnetic characteristics similar to those of the metal sheet is used to start the casting process and precedes the molten metal sheet through the magnet and forms a continuous sheet therewith. The magnet may be either U-shaped with a single racetrack coil or may be rectangular with a pair of facing bedstead coils.

  7. Energy use in selected metal casting facilities - 2003

    SciTech Connect (OSTI)

    Eppich, Robert E.

    2004-05-01

    This report represents an energy benchmark for various metal casting processes. It describes process flows and energy use by fuel type and processes for selected casting operations. It also provides recommendations for improving energy efficiency in casting.

  8. Effect of flask vibration time on casting integrity, Surface Penetration and Coating Inclusion in lost foam casting of Al-Si Alloy

    SciTech Connect (OSTI)

    Karimian, Majid [Dept. of Materials Engineering, Dept. of Mechanical Engineering, Khomeinishahr branch, Islamic Azad University-(Khomeinishahr- Isfahan) (Iran, Islamic Republic of); Idris, M. H. [Dept. of Manufacturing and Industrial Engineering, Faculty of Mechanical Engineering, University Technology Malaysia, Johor Bauru (Malaysia); Ourdjini, A.; Muthu, Kali [Dept. of Materials Engineering, Khomeinishahr branch, Islamic Azad University-(Khomeinishahr- Isfahan) (Iran, Islamic Republic of)

    2011-01-17

    The paper presents the result of an experimental investigation conducted on medium aluminum silicon alloy casting- LM6, using no-vacuum assisted lost foam casting process. The study is directed for establishing the relationship between the flask vibrations times developed for molded sample on the casting integrity, surface penetration and coating inclusion defects of the casting. Four different flask vibration times namely 180, 120, 90 and 60 sec. were investigated. The casting integrity was investigated in terms of fulfilling in all portions and edges. The surface penetration was measured using optical microscope whilst image analyzer was used to quantify the percentage of coating inclusion in the casting. The results show that vibration time has significant influence on the fulfilling as well as the internal integrity of the lost foam casting. It was found that the lower vibration time produced comparatively sound casing.

  9. Spray casting of metallic preforms

    DOE Patents [OSTI]

    Flinn, John E. (Idaho Falls, ID); Burch, Joseph V. (Shelley, ID); Sears, James W. (Niskayuna, NY)

    2000-01-01

    A metal alloy is melted in a crucible and ejected from the bottom of the crucible as a descending stream of molten metal. The descending stream is impacted with a plurality of primary inert gas jets surrounding the molten metal stream to produce a plume of atomized molten metal droplets. An inert gas is blown onto a lower portion of the plume with a plurality of auxiliary inert gas jets to deflect the plume into a more restricted pattern of high droplet density, thereby substantially eliminating unwanted overspray and resulting wasted material. The plume is projected onto a moving substrate to form a monolithic metallic product having generally parallel sides.

  10. Pyrophoric metal-carbon foam composites and methods of making the same

    DOE Patents [OSTI]

    Gash, Alexander E. (Brentwood, CA); Satcher, Jr., Joe H. (Patterson, CA); Simpson, Randall L. (Livermore, CA); Baumann, Theodore F. (Discovery Bay, CA); Worsley, Marcus A. (Belmont, CA)

    2012-05-08

    A method for creating a pyrophoric material according to one embodiment includes thermally activating a carbon foam for creating micropores therein; contacting the activated carbon foam with a liquid solution comprising a metal salt for depositing metal ions in the carbon foam; and reducing the metal ions in the foam to metal particles. A pyrophoric material in yet another embodiment includes a pyrophoric metal-carbon foam composite comprising a carbon foam having micropores and mesopores and a surface area of greater than or equal to about 2000 m.sup.2/g, and metal particles in the pores of the carbon foam. Additional methods and materials are also disclosed.

  11. Subcritical Measurements Multiple HEU Metal Castings

    SciTech Connect (OSTI)

    Mihalczo, John T [ORNL] [ORNL; Archer, Daniel E [ORNL] [ORNL; Wright, Michael C [ORNL] [ORNL

    2008-01-01

    Experiments with the standard annular highly enriched uranium (HEU) metal castings at Y-12 were performed in which up to 5 castings ({approx}90kg) were assembled in a tightly packed array with minimal spacing between castings. The fission chain multiplication process was initiated by a time tagged {sup 253}Cf spontaneously fissioning neutron source or time and directionally tagged neutrons from a small portable DT neutron generator and the prompt neutron time behavior measured with plastic scintillation detectors sensitive the fast neutron (>1 MeV) and gamma ray without distinction. These experiments were performed to provide data to benchmark methods for the calculation of the prompt neutron time behavior. Previous measurements with a single casting have been reported. This paper presents the experimental results for multiple castings. The prompt time decay was obtained by time coincidence correlation measurements between the detectors and the time tagged neutron source emission (equivalent to randomly pulsed neutron measurements) and between pairs of plastic scintillation detectors (equivalent to a 2-detector Rossi-alpha measurement). These standard HEU storage castings at the Y-12 plant had 5.000-in-OD, 3.500-in-ID, masses between 17,636 and 17,996 g, impurity content of 992 ppm, density of 18.75 g/cm{sup 3} and average enrichment of 93.16 wt % {sup 235}U. The castings were in tight fitting 025-in.-thick, 8.0-in-high stainless steel (SS-304) cylindrical cans for contamination control which were 8.0 in high. One can had an inside diameter of 3.0 in so that the Cf source could be located on the axes of this casting. Four 1 x 1 x 6 in plastic scintillators with the long dimension perpendicular to axes of the castings and adjacent to the outer surface of the casting cans were used. The detectors were enclosed in 1/4.-in.-thick lead shields on four 1 x 6 surfaces and on the 1 x 1 surface. The small surface of the lead shield was adjacent to the steel table. The photograph of the assembly of 5 casting with the detectors is given in Figure 1. The DT generator can be seen in the back with the time tagged neutrons aligned symmetrically around a line drawn from the generator through target spot and the center of the casting in the annular can seen in the foreground.

  12. Metal Casting Project Fact Sheet - Predicting Pattern Tooling and Casting

    SciTech Connect (OSTI)

    None

    2000-12-01

    Factors affecting casting dimension and tools to reduce their impact are being identified in this project.

  13. Foam and gel methods for the decontamination of metallic surfaces

    DOE Patents [OSTI]

    Nunez, Luis; Kaminski, Michael Donald

    2007-01-23

    Decontamination of nuclear facilities is necessary to reduce the radiation field during normal operations and decommissioning of complex equipment. In this invention, we discuss gel and foam based diphosphonic acid (HEDPA) chemical solutions that are unique in that these solutions can be applied at room temperature; provide protection to the base metal for continued applications of the equipment; and reduce the final waste form production to one step. The HEDPA gels and foams are formulated with benign chemicals, including various solvents, such as ionic liquids and reducing and complexing agents such as hydroxamic acids, and formaldehyde sulfoxylate. Gel and foam based HEDPA processes allow for decontamination of difficult to reach surfaces that are unmanageable with traditional aqueous process methods. Also, the gel and foam components are optimized to maximize the dissolution rate and assist in the chemical transformation of the gel and foam to a stable waste form.

  14. Volatile Species Retention During Metallic Fuel Casting

    SciTech Connect (OSTI)

    Randall S. Fielding; Douglas L. Proter

    2013-10-01

    Metallic nuclear fuels are candidate transmutation fuel forms for advanced fuel cycles. Through the operation of the Experimental Breeder Reactor II metallic nuclear fuels have been shown to be robust and easily manufactured. However, concerns have been raised concerning loss of americium during the casting process because of its high vapor pressure. In order to address these concerns a gaseous diffusion model was developed and a series of experiments using both manganese and samarium as surrogates for americium were conducted. The modeling results showed that volatility losses can be controlled to essentially no losses with a modest overpressure. Experimental results also showed volatile species retention down to no detectable losses through overpressure, although the loss values varied from the model results the same trend was seen. Bases on these results it is very probably that americium losses through volatility can be controlled to no detectable losses through application of a modest overpressure during casting.

  15. An Investigation and Characterization of Metal Foam Filled Double-Pipe Heat Exchangers

    E-Print Network [OSTI]

    Chen, Xi

    2014-01-01

    a metal foam filled double-pipe heat exchanger: a) Pressurein a metal foam filled double-pipe heat exchanger witha plain double-pipe heat exchanger: a) Total heat transfer

  16. Thermal Transport in Porous Media with Application to Fuel Cell Diffusion Media and Metal Foams

    E-Print Network [OSTI]

    Victoria, University of

    Thermal Transport in Porous Media with Application to Fuel Cell Diffusion Media and Metal Foams to Fuel Cell Diffusion Media and Metal Foams by Ehsan Sadeghi B.Sc., Sharif University of Technology, Iran of thermal transport phenomena in fuel cell gas diffusion layers (GDLs) and metal foams and describes new

  17. ITP Metal Casting: Energy Use in Selected Metalcasting Facilities...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Use in Selected Metalcasting Facilities - 2003 ITP Metal Casting: Energy Use in Selected Metalcasting Facilities - 2003 energyuseinselectedmetalcasting52804.pdf More Documents &...

  18. ITP Metal Casting: Corrosion Testing Practices - High Alloy Corrosion...

    Broader source: Energy.gov (indexed) [DOE]

    Documents & Publications FY 2009 Progress Report for Lightweighting Materials - 3. Automotive Metals - Cast Vehicle Technologies Office Merit Review 2015: Phase Transformation...

  19. ITP Metal Casting: Metalcasting Industry Technology Roadmap

    Office of Energy Efficiency and Renewable Energy (EERE)

    Castings are essential building blocks of U. S. industry. More than 90% of all mnaufactured, durable good and 100% of all manufacturing machinery contain castings.

  20. Method and mold for casting thin metal objects

    DOE Patents [OSTI]

    Pehrson, Brandon P; Moore, Alan F

    2014-04-29

    Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

  1. Metallic Fuel Casting Development and Parameter Optimization Simulations

    SciTech Connect (OSTI)

    R.S. Fielding; J. Crapps; C. Unal; J.R. Kennedy

    2013-03-01

    One of the advantages of metallic fuel is the abilility to cast the fuel slugs to near net shape with little additional processing. However, the high aspect ratio of the fuel is not ideal for casting. EBR-II fuel was cast using counter gravity injection casting (CGIC) but, concerns have been raised concerning the feasibility of this process for americium bearing alloys. The Fuel Cycle Research and Development program has begun developing gravity casting techniques suitable for fuel production. Compared to CGIC gravity casting does not require a large heel that then is recycled, does not require application of a vacuum during melting, and is conducive to re-usable molds. Development has included fabrication of two separate benchscale, approximately 300 grams, systems. To shorten development time computer simulations have been used to ensure mold and crucible designs are feasible and to identify which fluid properties most affect casting behavior and therefore require more characterization.

  2. Filler metal alloy for welding cast nickel aluminide alloys

    DOE Patents [OSTI]

    Santella, M.L.; Sikka, V.K.

    1998-03-10

    A filler metal alloy used as a filler for welding cast nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and cast in copper chill molds. 3 figs.

  3. Forming foam structures with carbon foam substrates

    DOE Patents [OSTI]

    Landingham, Richard L.; Satcher, Jr., Joe H.; Coronado, Paul R.; Baumann, Theodore F.

    2012-11-06

    The invention provides foams of desired cell sizes formed from metal or ceramic materials that coat the surfaces of carbon foams which are subsequently removed. For example, metal is located over a sol-gel foam monolith. The metal is melted to produce a metal/sol-gel composition. The sol-gel foam monolith is removed, leaving a metal foam.

  4. Fluxing agent for metal cast joining

    DOE Patents [OSTI]

    Gunkel, Ronald W. (Lower Burrell, PA); Podey, Larry L. (Greensburg, PA); Meyer, Thomas N. (Murrysville, PA)

    2002-11-05

    A method of joining an aluminum cast member to an aluminum component. The method includes the steps of coating a surface of an aluminum component with flux comprising cesium fluoride, placing the flux coated component in a mold, filling the mold with molten aluminum alloy, and allowing the molten aluminum alloy to solidify thereby joining a cast member to the aluminum component. The flux preferably includes aluminum fluoride and alumina. A particularly preferred flux includes about 60 wt. % CsF, about 30 wt. % AlF.sub.3, and about 10 wt. % Al.sub.2 O.sub.3.

  5. Liquid Metal Processing and Casting Experiences at the U.S. Department of Energy's Albany Research Center

    SciTech Connect (OSTI)

    Jablonski, Paul D.; Turner, Paul C.

    2005-09-01

    In this paper we will discuss some of the early pioneering work as well as some of our more recent research. The Albany Research Center (ARC) has been involved with the melting and processing of metals since it was established in 1942. In the early days, hardly anything was known about melting refractory or reactive metals and as such, virtually everything had to be developed in-house. Besides the more common induction heated air-melt furnaces, ARC has built and/or utilized a wide variety of furnaces including vacuum arc remelt ingot and casting furnaces, cold wall induction furnaces, electric arc furnaces, cupola furnaces and reverberatory furnaces. The melt size of these furnaces range from several grams to a ton or more. We have used these furnaces to formulate custom alloys for wrought applications as well as for such casting techniques as spin casting, investment casting and lost foam casting among many. Two early spin-off industrializations were Wah Chang (wrought zirconium alloys for military and commercial nuclear applications) and Oremet (both wrought and cast Ti). Both of these companies are now part of the ATI Allegheny Ludlum Corporation.

  6. A comparison of the marginal adaptation of cathode-arc vapor-deposited titanium and cast base metal copings.

    E-Print Network [OSTI]

    Wu, Jean C; Lai, Li-Chung; Sheets, Cherilyn G; Earthman, James; Newcomb, Robert

    2011-01-01

    invest- ment, and casting of metal alloys are potentialusing ti- tanium and base metal castings was that they havenique-sensitive method of casting this base metal alloy. The

  7. Electromagnetic augmentation for casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, J.R.

    1987-10-28

    Thin metal sheets are cast by magnetically levitating molten metal deposited in a model within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled by the water-cooled walls of the mold to form a solid metal sheet. A conducting shield is electrically coupled to the molten metal sheet to provide a return path for eddy currents induced in the metal sheet by the current in the AC conducting coils. In another embodiment, a DC conducting coil is coupled to the metal sheet for providing a direct current therein which interacts with the magnetic field to levitate the moving metal sheet. Levitation of the metal sheet in both molten and solid forms reduces its contact pressure with the mold walls while maintaining sufficient engagement therebetween to permit efficient conductive cooling by the mold through which a coolant fluid may be circulated. 8 figs.

  8. On the eective thermal conductivity of a three-dimensionally structured uid-saturated metal foam

    E-Print Network [OSTI]

    Daraio, Chiara

    thermal conductivity to a large extent, a fact that must be dealt with in the foam manufacturing process thermal conductivity in the volume averaged homogeneous energy equation. Antohe et al. [11] also requiredOn the eective thermal conductivity of a three- dimensionally structured ¯uid-saturated metal foam

  9. Modelling the dip coating process for hot metal castings

    E-Print Network [OSTI]

    McGuinness, Mark

    Modelling the dip coating process for hot metal castings Mark J. McGuinness #3; A.J. Roberts y #12; List of Figures 2 6 Modelling Coating Growth 17 6.1 Simple Conduction Model . . . . . . . . . . . . . . 23 6.3 Linear Temperature Model . . . . . . . . . . . . . . . . . . . 23 7 Estimates of Coating

  10. Implementation of Metal Casting Best Practices

    SciTech Connect (OSTI)

    None

    2007-01-01

    The project examined cases where metal casters had implemented ITP research results and the benefits they received due to that implementation. In cases where casters had not implemented those results, the project examined the factors responsible for that lack of implementation. The project also informed metal casters of the free tools and service offered by the ITP Technology Delivery subprogram.

  11. Filler metal alloy for welding cast nickel aluminide alloys

    DOE Patents [OSTI]

    Santella, Michael L. (Knoxville, TN); Sikka, Vinod K. (Oak Ridge, TN)

    1998-01-01

    A filler metal alloy used as a filler for welding east nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and east in copper chill molds.

  12. Electromagnetic augmentation for casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, John R. (Hinsdale, IL)

    1989-01-01

    Thin metal sheets are cast by magnetically levitating molten metal deposited in a mold within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled by the water-cooled walls of the mold to form a solid metal sheet. A conducting shield is electrically coupled to the molten metal sheet to provide a return path for eddy currents induced in the metal sheet by the current in the AC conducting coils. In another embodiment, a DC conducting coil is coupled to the metal sheet for providing a direct current therein which interacts with the magnetic field to levitate the moving metal sheet. Levitation of the metal sheet in both molten and solid forms reduces its contact pressure with the mold walls while maintaining sufficient engagement therebetween to permit efficient conductive cooling by the mold through which a coolant fluid may be circulated. The magnetic fields associated with the currents in the aforementioned coils levitate the molten metal sheet while the mold provides for its lateral and vertical confinement. A leader sheet having electromagnetic characteristics similar to those of the molten metal sheet is used to start the casing process and precedes the molten metal sheet through the yoke/coil arrangement and mold and forms a continuous sheet therewith. The yoke/coil arrangement may be either U-shaped with a single racetrack coil or may be rectangular with a pair of spaced, facing bedstead coils.

  13. Cooling system for continuous metal casting machines

    DOE Patents [OSTI]

    Draper, R.; Sumpman, W.C.; Baker, R.J.; Williams, R.S.

    1988-06-07

    A continuous metal caster cooling system is provided in which water is supplied in jets from a large number of small nozzles against the inner surface of rim at a temperature and with sufficient pressure that the velocity of the jets is sufficiently high that the mode of heat transfer is substantially by forced convection, the liquid being returned from the cooling chambers through return pipes distributed interstitially among the nozzles. 9 figs.

  14. Cooling system for continuous metal casting machines

    DOE Patents [OSTI]

    Draper, Robert (Churchill Boro, PA); Sumpman, Wayne C. (North Huntingdon, PA); Baker, Robert J. (Wilkins Township, Allegheny County, PA); Williams, Robert S. (Plum Borough, PA)

    1988-01-01

    A continuous metal caster cooling system is provided in which water is supplied in jets from a large number of small nozzles 19 against the inner surface of rim 13 at a temperature and with sufficient pressure that the velocity of the jets is sufficiently high that the mode of heat transfer is substantially by forced convection, the liquid being returned from the cooling chambers 30 through return pipes 25 distributed interstitially among the nozzles.

  15. A Vision for the U.S. Metal Casting Industry - 2002 and Beyond

    SciTech Connect (OSTI)

    None

    2002-05-01

    Chief executive officers and presidents from the foundry, die casting, and foundry supply industries developed the A Vision for the U.S. Metal Casting Industry - 2002 and Beyond document.

  16. ITP Metal Casting: Theoretical/Best Practice Energy Use in Metalcastin...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    TheoreticalBest Practice Energy Use in Metalcasting Operations ITP Metal Casting: TheoreticalBest Practice Energy Use in Metalcasting Operations doebestpractice052804.pdf More...

  17. Energy and Environmental Profile of the U.S. Metal Casting Industry

    SciTech Connect (OSTI)

    None

    1999-09-01

    This detailed report benchmarks the energy and environmental characteristics of the key technologies used in the major processes of the metal casting industry.

  18. Thermal conductivity and contact resistance of metal foams This article has been downloaded from IOPscience. Please scroll down to see the full text article.

    E-Print Network [OSTI]

    Bahrami, Majid

    distribution in metal foams is necessary for design and modelling of thermal-hydraulic systems incorporating conductivity and TCR in metal foams is described. Measurements are performed in a vacuum under varying

  19. Electromagnetic confinement for vertical casting or containing molten metal

    DOE Patents [OSTI]

    Lari, Robert J. (Aurora, IL); Praeg, Walter F. (Palos Park, IL); Turner, Larry R. (Naperville, IL)

    1991-01-01

    An apparatus and method adapted to confine a molten metal to a region by means of an alternating electromagnetic field. As adapted for use in the present invention, the alternating electromagnetic field given by B.sub.y =(2.mu..sub.o .rho.gy).sup.1/2 (where B.sub.y is the vertical component of the magnetic field generated by the magnet at the boundary of the region; y is the distance measured downward form the top of the region, .rho. is the metal density, g is the acceleration of gravity and .mu..sub.o is the permeability of free space) induces eddy currents in the molten metal which interact with the magnetic field to retain the molten metal with a vertical boudnary. As applied to an apparatus for the continuous casting of metal sheets or rods, metal in liquid form can be continuously introduced into the region defined by the magnetic field, solidified and conveyed away from the magnetic field in solid form in a continuous process.

  20. ITP Metal Casting: Advanced Melting Technologies: Energy Saving Concepts and Opportunities for the Metal Casting Industry

    Office of Energy Efficiency and Renewable Energy (EERE)

    The study examines current and emerging melting technologies and discusses their technical barriers to scale-up issues and research needed to advance these technologies, improving melting efficiency, lowering metal transfer heat loss, and reducing scrap.

  1. Cast Metals Coalition Technology Transfer and Program Management Final Report

    SciTech Connect (OSTI)

    Gwyn, Mike

    2009-03-31

    The Cast Metals Coalition (CMC) partnership program was funded to ensure that the results of the Department of Energy's (DOE) metalcasting research and development (R&D) projects are successfully deployed into industry. Specifically, the CMC program coordinated the transfer and deployment of energy saving technologies and process improvements developed under separately funded DOE programs and projects into industry. The transition of these technologies and process improvements is a critical step in the path to realizing actual energy savings. At full deployment, DOE funded metalcasting R&D results are projected to save 55% of the energy used by the industry in 1998. This closely aligns with DOE's current goal of driving a 25% reduction in industrial energy intensity by 2017. In addition to benefiting DOE, these energy savings provide metalcasters with a significant economic advantage. Deployment of already completed R&D project results and those still underway is estimated to return over 500% of the original DOE and industry investment. Energy savings estimates through December 2008 from the Energy-Saving Melting and Revert Reduction Technology (E-SMARRT) portfolio of projects alone are 12 x 1012 BTUs, with a projection of over 50 x 1012 BTUs ten years after program completion. These energy savings and process improvements have been made possible through the unique collaborative structure of the CMC partnership. The CMC team consists of DOE's Office of Industrial Technology, the three leading metalcasting technical societies in the U.S: the American Foundry Society; the North American Die Casting Association; and the Steel Founders Society of America; and the Advanced Technology Institute (ATI), a recognized leader in distributed technology management. CMC provides collaborative leadership to a complex industry composed of approximately 2,100 companies, 80% of which employ less than 100 people, and only 4% of which employ more than 250 people. Without collaboration, new technologies enabling energy efficiencies and environment-friendly improvements are slow to develop, and have trouble obtaining a broad application. The CMC team was able to effectively and efficiently transfer the results of DOE's metalcasting R&D projects to industry by utilizing and delivering the numerous communication vehicles identified in the proposal. The three metalcasting technical associations achieved significant technology transition results under this program. In addition to reaching over 23,000 people per year through Modern Casting and 28,000 through Engineered Casting Solutions, AFS had 84 national publications and reached over 1,200 people annually through Cast Metals Institute (CMI) education courses. NADCA's education department reached over 1,000 people each year through their courses, in addition to reaching over 6,000 people annually through Die Casting Engineer, and publishing 58 papers. The SFSA also published 99 research papers and reached over 1,000 people annually through their member newsletters. In addition to these communication vehicles, the CMC team conducted numerous technical committee meetings, project reviews, and onsite visits. All of these efforts to distribute the latest metalcasting technologies contributed to the successful deployment of DOE's R&D projects into industry. The DOE/CMC partnership demonstrated significant success in the identification and review of relevant and easy-to-implement metalcasting energy-saving processes and technologies so that the results are quickly implemented and become general practice. The results achieved in this program demonstrate that sustained technology transfer efforts are a critical step in the deployment of R&D projects to industry.

  2. Thermal Transport in Porous Media with Application to Fuel Cell Diffusion Media and Metal Foams

    E-Print Network [OSTI]

    Bahrami, Majid

    of thermal transport phenomena in fuel cell gas diffusion layers (GDLs) and metal foams and describes new transfer through the GDL is a key process in the design and operation of a proton exchange membrane (PEM program allows the separation of effective thermal conductivity and thermal contact resistance. For GDLs

  3. Shear properties on aluminum metal foams prepared by the melt route

    SciTech Connect (OSTI)

    Saenz, E. [UTRC GmbH, Aachen (Germany). Technologiezentrum; Baranda, P.S. [UTRC, S.L., Minano (Spain); Bonhomme, J. [ITMA, Coruno-Llanera (Spain). Parque Tecnologico de Asturias

    1998-12-31

    The shear modulus and shear strength of AlSi7Mg Aluminum foam with 15% (vol) of 13 {micro}m SiC particles were determined through shear testing. A foam slab with a density of 0.31 g/cm3 was supplied by Hydro Aluminium. Four samples were tested according to ASTM C 273-61. The specimens were bonded to steel load plates. The relative displacement of the plates was measured using two extensometers. In order to evaluate the effect of the cell size distribution on shear properties, cell size and material distribution analyses were carried out for the metal foam slab in areas close to those from which the shear specimens were extracted. A fast failure was observed after the maximum shear load. The failure in the samples were located in the central section of the slab mainly because the lower density was located there.

  4. CFD Modeling for Lost Foam White Side

    Broader source: Energy.gov [DOE]

    The lost foam casting process produces clean, high-quality castings with close tolerances. The most important advantage is that no cores (with binders) are required. One challenge in lost foam...

  5. Journal of Crystal Growth 287 (2006) 402407 Transition metals in photovoltaic-grade ingot-cast multicrystalline

    E-Print Network [OSTI]

    2006-01-01

    Journal of Crystal Growth 287 (2006) 402­407 Transition metals in photovoltaic-grade ingot-cast silicon (mc-Si) ingot casting for cost-effective solar cell wafer production. Highly sensitive to coat the inside of mc-Si ingot-casting crucibles, as well as the as-grown cast mc-Si material

  6. Casting Apparatus Including A Gas Driven Molten Metal Injector And Method

    DOE Patents [OSTI]

    Meyer, Thomas N. (Murrysville, PA)

    2004-06-01

    The casting apparatus (50) includes a holding vessel (10) for containing a supply of molten metal (12) and a casting mold (52) located above the holding vessel (10) and having a casting cavity (54). A molten metal injector (14) extends into the holding vessel (10) and is at least partially immersed in the molten metal (12) in the holding vessel (10). The molten metal injector (14) is in fluid communication with the casting cavity (54). The molten metal injector (14) has an injector body (16) defining an inlet opening (24) for receiving molten metal into the injector body (16). A gas pressurization source (38) is in fluid communication with the injector body (16) for cyclically pressurizing the injector body (16) and inducing molten metal to flow from the injector body (16) to the casting cavity (54). An inlet valve (42) is located in the inlet opening (24) in the injector body (16) for filling molten metal into the injector body (16). The inlet valve (42) is configured to prevent outflow of molten metal from the injector body (16) during pressurization and permit inflow of molten metal into the injector body (16) after pressurization. The inlet valve (42) has an inlet valve actuator (44) located above the surface of the supply of molten metal (12) and is operatively connected to the inlet valve (42) for operating the inlet valve (42) between open and closed positions.

  7. ITP Metal Casting: Corrosion Testing Practices ? High Alloy...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    AL Atlas Casting & Technology Tacoma, WA Southern Alloy Corp. Sylacauga, AL Stainless Foundry & Eng. Milwaukee, WI Wollaston Alloys Braintree, MA A Strong Energy Portfolio for a...

  8. Industrial Assessments in the Cast Metals Industry: Common Problems and Opportunities 

    E-Print Network [OSTI]

    Muller, M. R.; Barnish, T. J.; Kasten, D.

    1998-01-01

    to be considered include the melting area where the potential for inductive heating, waste heat recovery, preheating of metal charges, and optimization of combustion efficiency will be discussed. The casting area provides many opportunities including mold design...

  9. Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Light Metals Permanent Mold Casting

    SciTech Connect (OSTI)

    Fasoyinu, Yemi

    2014-03-31

    Current vehicles use mostly ferrous components for structural applications. It is possible to reduce the weight of the vehicle by substituting these parts with those made from light metals such as aluminum and magnesium. Many alloys and manufacturing processes can be used to produce these light metal components and casting is known to be most economical. One of the high integrity casting processes is permanent mold casting which is the focus of this research report. Many aluminum alloy castings used in automotive applications are produced by the sand casting process. Also, aluminum-silicon (Al-Si) alloys are the most widely used alloy systems for automotive applications. It is possible that by using high strength aluminum alloys based on an aluminum-copper (Al-Cu) system and permanent mold casting, the performance of these components can be enhanced significantly. This will also help to further reduce the weight. However, many technological obstacles need to be overcome before using these alloys in automotive applications in an economical way. There is very limited information in the open literature on gravity and low-pressure permanent mold casting of high strength aluminum alloys. This report summarizes the results and issues encountered during the casting trials of high strength aluminum alloy 206.0 (Al-Cu alloy) and moderate strength alloy 535.0 (Al-Mg alloy). Five engineering components were cast by gravity tilt-pour or low pressure permanent mold casting processes at CanmetMATERIALS (CMAT) and two production foundries. The results of the casting trials show that high integrity engineering components can be produced successfully from both alloys if specific processing parameters are used. It was shown that a combination of melt processing and mold temperature is necessary for the elimination of hot tears in both alloys.

  10. ITP Metal Casting: Energy Use in Selected Metalcasting Facilities- 2003

    Office of Energy Efficiency and Renewable Energy (EERE)

    This report represents an energy benchmark for various metalcasting processes. It describes process flows and energy use by fuel type and processes for selected casting operations. It also provides recommendations for improving energy efficiency in casti

  11. Composite carbon foam electrode

    DOE Patents [OSTI]

    Mayer, Steven T. (San Leandro, CA); Pekala, Richard W. (Pleasant Hill, CA); Kaschmitter, James L. (Pleasanton, CA)

    1997-01-01

    Carbon aerogels used as a binder for granularized materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid particles being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivty and power to system energy.

  12. Composite carbon foam electrode

    DOE Patents [OSTI]

    Mayer, S.T.; Pekala, R.W.; Kaschmitter, J.L.

    1997-05-06

    Carbon aerogels used as a binder for granulated materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid particles being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivity and power to system energy. 1 fig.

  13. Casting Apparatus Including A Gas Driven Molten Metal Injector And Method

    DOE Patents [OSTI]

    Trudel, David R. (Westlake, OH); Meyer, Thomas N. (Murrysville, PA); Kinosz, Michael J. (Apollo, PA); Arnaud, Guy (Morin Heights, CA); Bigler, Nicolas (Riviere-Beaudette, CA)

    2003-06-17

    The filtering molten metal injector system includes a holder furnace, a casting mold supported above the holder furnace, and at least one molten metal injector supported from a bottom side of the casting mold. The holder furnace contains a supply of molten metal. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The molten metal injector projects into the holder furnace. The molten metal injector includes a cylinder defining a piston cavity housing a reciprocating piston for pumping the molten metal upward from the holder furnace to the mold cavity. The cylinder and piston are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder or the piston includes a molten metal intake for receiving the molten metal into the piston cavity when the holder furnace contains molten metal. A conduit connects the piston cavity to the mold cavity. A molten metal filter is located in the conduit for filtering the molten metal passing through the conduit during the reciprocating movement of the piston. The molten metal intake may be a valve connected to the cylinder, a gap formed between the piston and an open end of the cylinder, an aperture defined in the sidewall of the cylinder, or a ball check valve incorporated into the piston. A second molten metal filter preferably covers the molten metal intake to the injector.

  14. Optimization of Design and Manufacturing Process of Metal Foam Filled Anti-Intrusion Bars

    SciTech Connect (OSTI)

    Villa, Andrea; Mussi, Valerio; Strano, Matteo

    2011-05-04

    The role of an anti-intrusion bar for automotive use is to absorb the kinetic energy of the colliding bodies that is partially converted into internal work of the bodies involved in the crash. The aim of this paper is to investigate the performances of a new kind of anti-intrusion bars for automotive use, filled with metallic foams. The reason for using a cellular material as a filler deals with its capacity to absorb energy during plastic deformation, while being lightweight. The study is the evolution of a previous paper presented by the authors at Esaform 2010 and will present new results and findings. It is conducted by evaluating some key technical issues of the manufacturing problem and by conducting experimental and numerical analyses. The evaluation of materials and shapes of the closed sections to be filled is made in the perspective of a car manufacturer (production costs, weight reduction, space availability in a car door, etc.). Experimentally, foams are produced starting from an industrial aluminium precursor with a TiH{sub 2} blowing agent. Bars are tested in three point bending, in order to evaluate their performances in terms of force-displacement response and other specific performance parameters. In order to understand the role of interface between the inner surface of the tube and the external surface of the foam, different kinds of interface are tested.

  15. ''Heat Transfer at the Mold-Metal Interface in Permanent Mold Casting of Aluminum Alloys'' Final Project Report

    SciTech Connect (OSTI)

    Professor R. D. Pehlke, Principal Investigator, Dr. John M. Cookson, Dr. Shouwei Hao, Dr. Prasad Krishna, Kevin T. Bilkey

    2001-12-14

    This project on heat transfer coefficients in metal permanent mold casting has been conducted in three areas. They are the theoretical study at the University of Michigan, the experimental investigation of squeeze casting at CMI-Tech Center (Now Hayes-Lemmerz Technical Center) and the experimental investigation of low pressure permanent mold casting at Amcast Automotive.

  16. Casting materials

    DOE Patents [OSTI]

    Chaudhry, Anil R. (Xenia, OH); Dzugan, Robert (Cincinnati, OH); Harrington, Richard M. (Cincinnati, OH); Neece, Faurice D. (Lyndurst, OH); Singh, Nipendra P. (Pepper Pike, OH)

    2011-06-14

    A foam material comprises a liquid polymer and a liquid isocyanate which is mixed to make a solution that is poured, injected or otherwise deposited into a corresponding mold. A reaction from the mixture of the liquid polymer and liquid isocyanate inside the mold forms a thermally collapsible foam structure having a shape that corresponds to the inside surface configuration of the mold and a skin that is continuous and unbroken. Once the reaction is complete, the foam pattern is removed from the mold and may be used as a pattern in any number of conventional casting processes.

  17. Engineering-Scale Development of Injection Casting Technology for Metal Fuel Cycle

    SciTech Connect (OSTI)

    Ogata, Takanari; Tsukada, Takeshi [Central Research Institute of Electric Power Industry - CRIEPI, Nuclear Technology Research Laboratory 2-11-1 Iwado-Kita, Komae, Tokyo 201-8511 (Japan)

    2007-07-01

    Engineering-scale injection casting tests were conducted in order to demonstrate the applicability of injection casting technology to the commercialized fast reactor fuel cycle. The uranium-zirconium alloy slugs produced in the tests were examined with reference to the practical slug specifications: average diameter tolerance {+-} 0.05 mm, local diameter tolerance {+-} 0.1 mm, density range 15.3 to 16.1 g/cm{sup 3}, zirconium content range 10 {+-} 1 wt% and total impurity (C, N, O, Si) <2000 ppm, which were provisionally determined. Most of the slugs satisfied these specifications, except for zirconium content. The impurity level was sufficiently low even though the residual and scrapped alloys were repeatedly recycled. The weight ratio of injected metal to charged metal was sufficiently high for a high process throughput. The injection casting technology will be applicable to the commercialized fuel cycle when the issue of zirconium content variation is resolved. (authors)

  18. Metallic Reinforcement of Direct Squeeze Die Casting Aluminum Alloys for Improved Strength and Fracture Resistance

    SciTech Connect (OSTI)

    D. Schwam: J.F. Wallace: Y. Zhu: J.W. Ki

    2004-10-01

    The utilization of aluminum die casting as enclosures where internal equipment is rotating inside of the casting and could fracture requires a strong housing to restrain the fractured parts. A typical example would be a supercharger. In case of a failure, unless adequately contained, fractured parts could injure people operating the equipment. A number of potential reinforcement materials were investigated. The initial work was conducted in sand molds to create experimental conditions that promote prolonged contact of the reinforcing material with molten aluminum. Bonding of Aluminum bronze, Cast iron, and Ni-resist inserts with various electroplated coatings and surface treatments were analyzed. Also toughening of A354 aluminum cast alloy by steel and stainless steel wire mesh with various conditions was analyzed. A practical approach to reinforcement of die cast aluminum components is to use a reinforcing steel preform. Such performs can be fabricated from steel wire mesh or perforated metal sheet by stamping or deep drawing. A hemispherical, dome shaped casting was selected in this investigation. A deep drawing die was used to fabricate the reinforcing performs. The tendency of aluminum cast enclosures to fracture could be significantly reduced by installing a wire mesh of austenitic stainless steel or a punched austenitic stainless steel sheet within the casting. The use of reinforcements made of austenitic stainless steel wire mesh or punched austenitic stainless steel sheet provided marked improvement in reducing the fragmentation of the casting. The best strengthening was obtained with austenitic stainless steel wire and with a punched stainless steel sheet without annealing this material. Somewhat lower results were obtained with the annealed punched stainless steel sheet. When the annealed 1020 steel wire mesh was used, the results were only slightly improved because of the lower mechanical properties of this unalloyed steel. The lowest results were obtained with unreinforced 356 aluminum casting. Good strength can be obtained with a sound die casting without any defects produced by squeeze casting. The use of higher pressure to produce the squeeze casting has been shown to increase the strength of a hemispherical dome casting. This dome shape casting has been produced both with and without reinforcement and tested to determine its pressure resistance under internal pressure of water. Only a slight improvement in strength could be determined because of water leaks at the seal between hemispherical dome and its flat supporting side. However, when the ability of the casting was tested under the compressive force of a plunger, the strengthening effect of wire mesh or sheet was evident. Higher loads to failure were obtained because of the reinforcement of the stainless steel wire and punched sheet. Rather than a sudden failure occurring, the reinforcement of the stainless steel wire or the punched hard stainless steel sheet held the material together and prevented any loss of the fractured casting to the surroundings. Unalloyed steel did not have the required strength or mechanical properties to increase the properties of the casting.

  19. Pulsed Neutron Measurments With A DT Neutron Generator for an Annular HEU Uranium Metal Casting

    SciTech Connect (OSTI)

    Mihalczo, John T [ORNL; Archer, Daniel E [ORNL; Wright, Michael C [ORNL; Mullens, James Allen [ORNL

    2007-09-01

    Measurements were performed with a single annular, stainless-steel-canned casting of uranium (93.17 wt% 235U) metal ( ~18 kg) to provide data to verify calculational methods for criticality safety. The measurements used a small portable DT generator with an embedded alpha detector to time and directionally tag the neutrons from the generator. The center of the time and directional tagged neutron beam was perpendicular to the axis of the casting. The radiation detectors were 1x1x6 in plastic scintillators encased in 0.635-cm-thick lead shields that were sensitive to neutrons above 1 MeV in energy. The detector lead shields were adjacent to the casting and the target spot of the generator was about 3.8 cm from the casting at the vertical center. The time distribution of the fission induced radiation was measured with respect to the source event by a fast (1GHz) processor. The measurements described in this paper also include time correlation measurements with a time tagged spontaneously fissioning 252Cf neutron source, both on the axis and on the surface of the casting. Measurements with both types of sources are compared. Measurements with the DT generator closely coupled with the HEU provide no more additional information than those with the Cf source closely coupled with the HEU and are complicated by the time and directionally tagged neutrons from the generator scattering between the walls and floor of the measurements room and the casting while still above detection thresholds.

  20. Graded pitch electromagnetic pump for thin strip metal casting systems

    DOE Patents [OSTI]

    Kuznetsov, Stephen B. (Pittsburgh, PA)

    1986-01-01

    A metal strip casing system is provided with an electromagnetic pump which includes a pair of primary blocks having a graded pole pitch, polyphase ac winding and being arranged on opposite sides of a movable heat sink. A nozzle is provided for depositing liquid metal on the heat sink such that the resulting metal strip and heat sink combination is subjected to a longitudinal electromagnetic field which increases in wavelength in the direction of travel of the heat sink, thereby subjecting the metal and heat sink to a longitudinal force having a magnitude which increases in the direction of travel.

  1. Graded pitch electromagnetic pump for thin strip metal casting systems

    DOE Patents [OSTI]

    Kuznetsov, S.B.

    1986-04-01

    A metal strip casing system is provided with an electromagnetic pump which includes a pair of primary blocks having a graded pole pitch, polyphase ac winding and being arranged on opposite sides of a movable heat sink. A nozzle is provided for depositing liquid metal on the heat sink such that the resulting metal strip and heat sink combination is subjected to a longitudinal electromagnetic field which increases in wavelength in the direction of travel of the heat sink, thereby subjecting the metal and heat sink to a longitudinal force having a magnitude which increases in the direction of travel. 4 figs.

  2. Method for determining molten metal pool level in twin-belt continuous casting machines

    DOE Patents [OSTI]

    Kaiser, Timothy D. (Colchester, VT); Daniel, Sabah S. (Pittsburgh, PA); Dykes, Charles D. (Milton, VT)

    1989-03-21

    A method for determining level of molten metal in the input of a continuous metal casting machine having at least one endless, flexible, revolving casting belt with a surface which engages the molten metal to be cast and a reverse, cooled surface along which is directed high velocity liquid coolant includes the steps of predetermining the desired range of positions of the molten metal pool and positioning at least seven heat-sensing transducers in bearing contact with the moving reverse belt surface and spaced in upstream-downstream relationship relative to belt travel spanning the desired pool levels. A predetermined temperature threshold is set, somewhat above coolant temperature and the output signals of the transducer sensors are scanned regarding their output signals indicative of temperatures of the moving reverse belt surface. Position of the molten pool is determined using temperature interpolation between any successive pair of upstream-downstream spaced sensors, which follows confirmation that two succeeding downstream sensors are at temperature levels exceeding threshold temperature. The method accordingly provides high resolution for determining pool position, and verifies the determined position by utilizing full-strength signals from two succeeding downstream sensors. In addition, dual sensors are used at each position spanning the desired range of molten metal pool levels to provide redundancy, wherein only the higher temperature of each pair of sensors at a station is utilized.

  3. Apparatus for injection casting metallic nuclear energy fuel rods

    DOE Patents [OSTI]

    Seidel, Bobby R. (Idaho Falls, ID); Tracy, Donald B. (Firth, ID); Griffiths, Vernon (Butte, MT)

    1991-01-01

    Molds for making metallic nuclear fuel rods are provided which present reduced risks to the environment by reducing radioactive waste. In one embodiment, the mold is consumable with the fuel rod, and in another embodiment, part of the mold can be re-used. Several molds can be arranged together in a cascaded manner, if desired, or several long cavities can be integrated in a monolithic multiple cavity re-usable mold.

  4. Measurement of Heat Flux at Metal-Mold Interface during Casting Solidification

    SciTech Connect (OSTI)

    Sabau, Adrian S [ORNL

    2006-01-01

    All previous studies on interfacial heat transfer coefficient have been based on indirect methods for estimating the heat flux that employed either inverse heat transfer analysis procedures or instrumentation arrangements to measure temperatures and displacements near the metal-mold interface. In this paper, the heat transfer at the metal-mold interfaces is investigated using a sensor for the direct measurement of heat flux. The heat flux sensor (HFS) was rated for 700oC and had a time response of less than 10 ms. Casting experiments were conducted using graphite molds for aluminum alloy A356. Several casting experiments were performed using a graphite coating and a boron nitride coating. The measurement errors were estimated. The temperature of the mold surface was provided by the HFS while the temperature of the casting surface was measured using a thermocouple. Results for the heat transfer coefficients were obtained based on measured heat flux and temperatures. Four stages were clearly identified for the variation in time of the heat flux. Values of the heat transfer coefficient were in good agreement with data from previous studies.

  5. Advanced Pattern Material for Investment Casting Applications

    SciTech Connect (OSTI)

    F. Douglas Neece Neil Chaudhry

    2006-02-08

    Cleveland Tool and Machine (CTM) of Cleveland, Ohio in conjunction with Harrington Product Development Center (HPDC) of Cincinnati, Ohio have developed an advanced, dimensionally accurate, temperature-stable, energy-efficient and cost-effective material and process to manufacture patterns for the investment casting industry. In the proposed technology, FOPAT (aFOam PATtern material) has been developed which is especially compatible with the investment casting process and offers the following advantages: increased dimensional accuracy; increased temperature stability; lower cost per pattern; less energy consumption per pattern; decreased cost of pattern making equipment; decreased tooling cost; increased casting yield. The present method for investment casting is "the lost wax" process, which is exactly that, the use of wax as a pattern material, which is then melted out or "lost" from the ceramic shell. The molten metal is then poured into the ceramic shell to produce a metal casting. This process goes back thousands of years and while there have been improvements in the wax and processing technology, the material is basically the same, wax. The proposed technology is based upon an established industrial process of "Reaction Injection Molding" (RIM) where two components react when mixed and then "molded" to form a part. The proposed technology has been modified and improved with the needs of investment casting in mind. A proprietary mix of components has been formulated which react and expand to form a foam-like product. The result is an investment casting pattern with smooth surface finish and excellent dimensional predictability along with the other key benefits listed above.

  6. THE CHOICE OF THE PROPER REFRACTORY FOR THE CASTING OF HIGH MELTING ELECTROPOSITIVE METALS

    E-Print Network [OSTI]

    Brewer, Leo

    2008-01-01

    Hefractory for the Casting of High Melting Electropositiveof the Proper Hefractor'""y" for the Casting of High Meltingof one mole percent o If the casting is done quickly so that

  7. Energy Saving Melting and Revert Reduction (E-SMARRT): Precision Casting of Steel

    SciTech Connect (OSTI)

    Dr. Von L. Richards

    2011-09-30

    This project addresses improvements in metal casting processes by reducing scrap and reducing the cost of production, due to scrap reduction from investment casting and yield improvement offered by lost foam casting as compared to no-bake or green sand molding. The objectives for the investment casting portion of the subtask are to improve knowledge of fracture toughness of mold shells and the sources of strength limiting flaws and to understand the effects of wax reclamation procedures on wax properties. Applying 'clean steel' approaches to pouring technology and cleanliness in investment casting of steel are anticipated to improve incoming materials inspection procedures as they affect the microstructure and toughness of the shell. This project focused on two areas of study in the production of steel castings to reduce scrap and save energy: (1) Reducing the amount of shell cracking in investment cast steel production; (2) Investigate the potential of lost foam steel casting The basic findings regarding investment casting shell cracking were: (1) In the case of post pouring cracking, this could be related to phase changes in silica upon cooling and could be delayed by pouring arrangement strategies that maintained the shell surface at temperature for longer time. Employing this delay resulted in less adherent oxidation of castings since the casting was cooler at the time o fair exposure. (2) A model for heat transfer through water saturated shell materials under steam pressure was developed. (3) Initial modeling result of autoclave de-waxing indicated the higher pressure and temperature in the autoclave would impose a steeper temperature gradient on the wax pattern, causing some melt flow prior to bulk expansion and decreasing the stress on the green shell. Basic findings regarding lost foam casting of steel at atmospheric pressure: (1) EPS foam generally decomposes by the collapse mode in steel casting. (2) There is an accumulation of carbon pick-up at the end of the casting opposite the gate. (3) It is recommended that lost foam castings in steel be gated for a quiescent fill in an empty cavity mold to prevent foam occlusion defects from the collapse mode. The energy benefit is primarily in yield savings and lower casting weight per function due to elimination of draft and parting lines for the larger lost foam castings. For the smaller investment casting, scrap losses due to shell cracking will be reduced. Both of these effects will reduce the metal melted per good ton of castings. There will also be less machine stock required per casting which is a yield savings and a small additional energy savings in machining. Downstream savings will come from heavy truck and railroad applications. Application of these processes to heavy truck castings will lighten the heavy truck fleet by about ten pounds per truck. Using ten years to achieve full penetration of the truck fleet at linear rate this will result in a fuel savings of 131 trillion BTU over ten years.

  8. W. Zhou, Z.M. Xu / Journal of Materials Processing Technology 63 (1997) 358-363 Casting of SiC Reinforced Metal Matrix Composites

    E-Print Network [OSTI]

    Zhou, Wei

    1997-01-01

    . This observation can also be explained by the thermal lag model proposed. Keywords: casting, metal matrixW. Zhou, Z.M. Xu / Journal of Materials Processing Technology 63 (1997) 358-363 358 Casting of SiC Reinforced Metal Matrix Composites W. Zhou*, Z. M. Xu** * School of Mechanical and Production Engineering

  9. Image Reconstruction of a Metal Fill Industrial Process Using Genetic Programming Alaa Al-Afeef

    E-Print Network [OSTI]

    Fernandez, Thomas

    the characteristic of the molten metal in Lost Foam Casting (LFC) process [12], [13] and many others. B. ECT SensorImage Reconstruction of a Metal Fill Industrial Process Using Genetic Programming Alaa Al-field and Ill-condition characteristic of ECT. The basic idea of the ECT for image re- construction for a metal

  10. Ceramic plasma-sprayed coating of melting crucibles for casting metal fuel slugs

    SciTech Connect (OSTI)

    K.H. Kim; C.T. Lee; C.B. Lee; R.S. Fielding; J.R. Kennedy

    2013-10-01

    Thermal cycling and melt reaction studies of ceramic coatings plasma-sprayed on Nb substrates were carried out to evaluate the performance of barrier coatings for metallic fuel casting applications. Thermal cycling tests of the ceramic plasma-sprayed coatings to 1450 degrees C showed that HfN, TiC, ZrC, and Y2O3 coating had good cycling characteristics with few interconnected cracks even after 20 cycles. Interaction studies by 1550 degrees C melt dipping tests of the plasma-sprayed coatings also indicated that HfN and Y2O3 do not form significant reaction layer between U–20 wt.% Zr melt and the coating layer. Plasma-sprayed Y2O3 coating exhibited the most promising characteristics among HfN, TiC, ZrC, and Y2O3 coating.

  11. Waste minimization assessment for a manufacturer of iron castings and fabricated sheet metal parts

    SciTech Connect (OSTI)

    Fleischman, M.; Harris, J.J.; Handmaker, A.; Looby, G.P.

    1995-08-01

    The U.S. Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-size manufacturers who want to minimize their generation of waste but who lack the expertise to do so. Waste Minimization Assessment Centers (WMACs) were established at selected universities and procedures were adapted from the EPA Waste Minimization Opportunity Assessment Manual. That document has been superseded by the Facility Pollution Prevention Guide. The WMAC team at the University of Louisville performed an assessment at a plant that manufactures iron castings and fabricated sheet metal parts. Foundry operations include mixing and mold formation, core making, metal pouring, shakeout, finishing, and painting. Cutting, shaping, and welding are the principal metal fabrication operations. The team`s report, detailing findings and recommendations indicated that paint-related wastes are generated in large quantities, and that significant waste reduction and cost savings could be realized by installing a dry powder coating system or by replacing conventional air spray paint guns with high-volume low-pressure spray guns. This research brief was developed by the principal investigators and EPA`s National Risk Management Research Laboratory, Cincinnati, OH, to announce key findings of an ongoing research project that is fully documented in a separate report of the same title available from University City Science Center.

  12. Report of Separate Effects Testing for Modeling of Metallic Fuel Casting Process

    SciTech Connect (OSTI)

    Crapps, Justin M. [Los Alamos National Laboratory; Galloway, Jack D. [Los Alamos National Laboratory; Decroix, David S. [Los Alamos National Laboratory; Korzekwa, David A. [Los Alamos National Laboratory; Aikin, Robert M. Jr. [Los Alamos National Laboratory; Unal, Cetin [Los Alamos National Laboratory; Fielding, R. [Idaho National Laboratory; Kennedy, R [Idaho National Laboratory

    2012-06-29

    In order to give guidance regarding the best investment of time and effort in experimental determination of parameters defining the casting process, a Flow-3D model of the casting process was used to investigate the most influential parameters regarding void fraction of the solidified rods and solidification speed for fluid flow parameters, liquid heat transfer parameters, and solid heat transfer parameters. Table 1 summarizes the most significant variables for each of the situations studied. A primary, secondary, and tertiary effect is provided for fluid flow parameters (impacts void fraction) and liquid heat transfer parameters (impacts solidification). In Table 1, the wetting angle represents the angle between the liquid and mold surface as pictured in Figure 1. The viscosity is the dynamic viscosity of the liquid and the surface tension is the property of the surface of a liquid that allows it to resist an external force. When only considering solid heat transfer properties, the variations from case to case were very small. Details on this conclusion are provided in the section considering solid heat transfer properties. The primary recommendation of the study is to measure the fluid flow parameters, specifically the wetting angle, surface tension, and dynamic viscosity, in order of importance, as well as the heat transfer parameters latent heat and specific heat of the liquid alloy. The wetting angle and surface tension can be measured simultaneously using the sessile drop method. It is unclear whether there is a temperature dependency in these properties. Thus measurements for all three parameters are requested at 1340, 1420, and 1500 degrees Celsius, which correspond to the minimum, middle, and maximum temperatures of the liquid alloy during the process. In addition, the heat transfer coefficient between the mold and liquid metal, the latent heat of transformation, and the specific heat of the liquid metal all have strong influences on solidification. These parameters should be measured to achieve better simulation fidelity. Information on all the mentioned parameters is virtually nonexistent. Presently, all the parameters within the casting model are estimates based on pure U, or another alloy such as U-Ni.

  13. Molten metal holder furnace and casting system incorporating the molten metal holder furnace

    DOE Patents [OSTI]

    Kinosz, Michael J. (Apollo, PA); Meyer, Thomas N. (Murrysville, PA)

    2003-02-11

    A bottom heated holder furnace (12) for containing a supply of molten metal includes a storage vessel (30) having sidewalls (32) and a bottom wall (34) defining a molten metal receiving chamber (36). A furnace insulating layer (42) lines the molten metal receiving chamber (36). A thermally conductive heat exchanger block (54) is located at the bottom of the molten metal receiving chamber (36) for heating the supply of molten metal. The heat exchanger block (54) includes a bottom face (65), side faces (66), and a top face (67). The heat exchanger block (54) includes a plurality of electrical heaters (70) extending therein and projecting outward from at least one of the faces of the heat exchanger block (54), and further extending through the furnace insulating layer (42) and one of the sidewalls (32) of the storage vessel (30) for connection to a source of electrical power. A sealing layer (50) covers the bottom face (65) and side faces (66) of the heat exchanger block (54) such that the heat exchanger block (54) is substantially separated from contact with the furnace insulating layer (42).

  14. Capacitor with a composite carbon foam electrode

    DOE Patents [OSTI]

    Mayer, Steven T. (San Leandro, CA); Pekala, Richard W. (Pleasant Hill, CA); Kaschmitter, James L. (Pleasanton, CA)

    1999-01-01

    Carbon aerogels used as a binder for granularized materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid partides being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivity and power to system energy.

  15. Capacitor with a composite carbon foam electrode

    DOE Patents [OSTI]

    Mayer, S.T.; Pekala, R.W.; Kaschmitter, J.L.

    1999-04-27

    Carbon aerogels used as a binder for granularized materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid particles being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivity and power to system energy. 1 fig.

  16. Method for fabricating composite carbon foam

    DOE Patents [OSTI]

    Mayer, Steven T. (San Leandro, CA); Pekala, Richard W. (Pleasant Hill, CA); Kaschmitter, James L. (Pleasanton, CA)

    2001-01-01

    Carbon aerogels used as a binder for granularized materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid particles being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivity and power to system energy.

  17. MCWASP, Modeling of Casting, Welding and Advanced Solidification Processes XI TMS (The Minerals, Metals & Materials Society),

    E-Print Network [OSTI]

    Zabaras, Nicholas J.

    at the bottom of the casting due to shrinkage driven fluid flow leads to a non-uniform solute distributionMCWASP, Modeling of Casting, Welding and Advanced Solidification Processes XI TMS (The Minerals, Aluminum alloys, Cast surfaces, Mold topography, Inverse segregation, Imperfect contact, Air-gaps, Solid

  18. Investigation of Heat Transfer at the Mold/Metal Interface in Permanent Mold Casting of Light Alloys

    SciTech Connect (OSTI)

    Robert D. Pehlke; John T. Berry

    2005-12-16

    Accurate modeling of the metal casting process prior to creating a mold design demands reliable knowledge of the interfacial heat transfer coefficient at the mold metal interface as a function of both time and location. The phenomena concerned with the gap forming between the mold and the solidifying metal are complex but need to be understood before any modeling is attempted. The presence of mold coatings further complicates the situation. A commercial casting was chosen and studied in a gravity permanent mold casting process. The metal/mold interfacial heat transfer coefficient (IHTC) was the focus of the research. A simple, direct method has been used to evaluate the IHTC. Both the simulation and experiments have shown that a reasonably good estimate of the heat transfer coefficient could be made in the case studied. It has been found that there is a good agreement between experiments and simulations in the temperature profiles during the solidification process, given that the primary mechanism of heat transfer across the gap in permanent mold casting of light alloys is by conduction across the gap. The procedure utilized to determine the interfacial heat transfer coefficient can be applied to other casting processes. A recently completed project involving The University of Michigan and Mississippi State University, together with several industrial partners, which was supported by the USDOE through the Cast Metals Coalition, examined a number of cases of thermal contact. In an investigation which gave special consideration to the techniques of measurement, several mold coatings were employed and results presented as a function of time. Realistic conditions of coating thickness and type together with an appropriate combination of mold preheat and metal pouring temperature were strictly maintained throughout the investigation. Temperature sensors, in particular thermocouples, play an important part in validating the predictions of solidification models. Cooling curve information, as well as temperature gradient history both in the solidifying metal and within the mold are invariably required to be validated. This validation depends upon the response of the sensor concerned, but also on its own effect upon the thermal environment. A joint university/industry team has completed an investigation of the invasive effects of thermocouples upon temperature history in permanent molds determining the degree of uncertainty associated with placement and indicating how the time-temperature history may be recovered. In addition to its relevance to the all important study of thermal contact of the casting with metallic molds, the observations also impact the determination of heat flux and interfacial heat transfer coefficients. In these respects the study represents the first of its kind that has tackled the problem in depth for permanent mold castings. An important ramification of this investigation has been the errors likely to be encountered in mold temperature measurement with thin section aluminum castings, especially with respect to the plans for thermocouple placement. A comparison between the degree of uncertainty experienced in sand molds compared with that found in permanent molds reveals that the associated problems have a lesser impact. These conclusions and the related recommendations have been disseminated to industry and the technical community through project reports and publications.

  19. Synthesis of Graphene Layers from Metal-Carbon Melts: Nucleation and Growth Kinetics

    E-Print Network [OSTI]

    Amini, Shaahin

    2012-01-01

    Complete Casting Handbook: Metal Casting Processes,Solidification and Casting of Metals, The Metal Society, [Solidification and Casting of Metals Sheffield, UK, 1977. [

  20. Multifaced stone and ceramic moulds from Bronze Age Anatolia : building an analytical protocol of mould properties and behavior during the process of metal casting

    E-Print Network [OSTI]

    Biçer, Katherine K. (Katherine Kershen)

    2005-01-01

    A three phase analytical protocol is developed to systematize the study of multifaceted serpentinite bronze-casting moulds from Bronze Age Anatolia (ca. 3500-1700 B.C.). These moulds represent a class of metal processing ...

  1. Computational modeling of structure of metal matrix composite in centrifugal casting process

    SciTech Connect (OSTI)

    Zagorski, Roman [Department of Electrotechnology, Faculty of Materials Science and Metallurgy, Silesian University of Technology, ul. Krasinskiego 8, 40-019, Katowice (Poland)

    2007-04-07

    The structure of alumina matrix composite reinforced with crystalline particles obtained during centrifugal casting process are studied. Several parameters of cast process like pouring temperature, temperature, rotating speed and size of casting mould which influent on structure of composite are examined. Segregation of crystalline particles depended on other factors such as: the gradient of density of the liquid matrix and reinforcement, thermal processes connected with solidifying of the cast, processes leading to changes in physical and structural properties of liquid composite are also investigated. All simulation are carried out by CFD program Fluent. Numerical simulations are performed using the FLUENT two-phase free surface (air and matrix) unsteady flow model (volume of fluid model - VOF) and discrete phase model (DPM)

  2. Synthesis of open-cell metal foams by templated directed vapor deposition

    E-Print Network [OSTI]

    Wadley, Haydn

    , Derek D. Hass, David J. Sypeck, and Haydn N.G. Wadley Department of Materials Science and Engineering, School of Engineering and Applied Science, University of Virginia, Charlottesville, Virginia 22904) and Metapore (Soci- e`te` Sorapec, Fontenay Sous Bois, France) for use in Ni­ Cd and Ni­metal hydride batteries

  3. PARAMETRIC EFFECTS OF ANTI-FOAM COMPOSITION, SIMULANT PROPERTIES AND NOBLE METALS ON THE GAS HOLDUP AND RELEASE OF A NON-NEWTONIAN WASTE SLURRY SIMULANT

    SciTech Connect (OSTI)

    Guerrero, H; Charles Crawford, C; Mark Fowley, M

    2008-08-07

    Gas holdup tests were performed in bench-scale and small-scale mechanically-agitated mixing systems at the Savannah River National Laboratory (SRNL) for a simulant of waste from the Hanford Tank 241-AZ-101. These featured additions of DOW Corning Q2-3183A anti-foam agent. Results indicated that this anti-foam agent (AFA) increased gas holdup in the waste simulant by about a factor of four and, counter-intuitively, that the holdup increased as the non-newtonian simulant shear strength decreased (apparent viscosity decreased). Such results raised the potential of increased flammable gas retention in Hanford Waste Treatment and Immobilization Plant (WTP) vessels mixed by air sparging and pulse-jet mixers (PJMs) during a Design Basis Event (DBE). Additional testing was performed to determine the effects of simulant properties, composition of alternate AFAs, and presence of trace noble metals. Key results are that: (1) Increased gas holdup resulting from addition of Q2-3183A is due to a decrease in surface tension that supports small bubbles which have low rise velocities. (2) Dow Corning 1520-US AFA shows it to be a viable replacement to Dow Corning Q2-3183A AFA. This alternative AFA, however, requires significantly higher dosage for the same anti-foam function. (3) Addition of noble metals to the AZ-101 waste simulant does not produce a catalytic gas retention effect with the AFA.

  4. Prompt Neutron Time Decay in Single HEU and DU Metal Annular Storage Castings

    SciTech Connect (OSTI)

    Pena, Kirsten E [ORNL] [ORNL; McConchie, Seth M [ORNL] [ORNL; Mihalczo, John T [ORNL] [ORNL

    2010-01-01

    Previous measurements of highly enriched uranium (HEU) storage castings performed by Oak Ridge National Laboratory (ORNL) at the Y-12 National Security Complex showed a prompt neutron time decay that is not exponential. These measurements showed that multiple time constants originating from multiplication, time-of-flight, scattering in the assembly and room return could be associated with this prompt neutron decay. In this work, the contribution not associated with neutron multiplication was investigated via measurements with a depleted uranium (DU) casting. The measurements at ORNL used an annular (5.0-in OD, 3.5-in ID, 6.0-in H) DU casting with a time-tagged 252Cf source, centered vertically on the axis, and four closely coupled 1 1 6-in.-long plastic scintillators with -in.- thick lead shielding adjacent to the outer surface of the casting. This setup was identical to the configuration used in the previously performed measurements with HEU castings at Y-12. The time correlation between fission events and detections in the plastic scintillators was measured, as well as the time distribution of coincidences between multiple detectors within a 512-ns time window. The measurement results were then compared to MCNP-PoliMi calculations and the previous HEU measurements. Time constants from decay fits to the HEU and DU data were compared to characterize the contributions resulting from multiplication, time-of-flight, and scattering.

  5. A comparison of the marginal adaptation of cathode-arc vapor-deposited titanium and cast base metal copings.

    E-Print Network [OSTI]

    Wu, Jean C; Lai, Li-Chung; Sheets, Cherilyn G; Earthman, James; Newcomb, Robert

    2011-01-01

    Marginal fit of gold inlay castings. J Prosthet Dent 1966;filling and porosity in castings of titanium. Dent Matera b Wu et al alloy types, casting procedures, por- celain

  6. Report on Development of Concepts for the Advanced Casting System in Support of the Deployment of a Remotely Operable Research Scale Fuel Fabrication Facility for Metal Fuel

    SciTech Connect (OSTI)

    Ken Marsden

    2007-03-01

    Demonstration of recycle processes with low transuranic losses is key to the successful implementation of the Global Nuclear Energy Partnership strategy to manage spent fuel. It is probable that these recycle processes will include remote fuel fabrication. This report outlines the strategy to develop and implement a remote metal fuel casting process with minimal transuranic losses. The approach includes a bench-scale casting system to develop materials, methods, and perform tests with transuranics, and an engineering-scale casting system to demonstrate scalability and remote operability. These systems will be built as flexible test beds allowing exploration of multiple fuel casting approaches. The final component of the remote fuel fabrication demonstration culminates in the installation of an advanced casting system in a hot cell to provide integrated remote operation experience with low transuranic loss. Design efforts and technology planning have begun for the bench-scale casting system, and this will become operational in fiscal year 2008, assuming appropriate funding. Installation of the engineering-scale system will follow in late fiscal year 2008, and utilize materials and process knowledge gained in the bench-scale system. Assuming appropriate funding, the advanced casting system will be installed in a remote hot cell at the end of fiscal year 2009.

  7. National Metal Casting Research Institute final report. Development of an automated ultrasonic inspection cell for detecting subsurface discontinuities in cast gray iron. Volume 3

    SciTech Connect (OSTI)

    Burningham, J.S.

    1995-08-01

    This inspection cell consisted of an ultrasonic flaw detector, transducer, robot, immersion tank, computer, and software. Normal beam pulse-echo ultrasonic nondestructive testing, using the developed automated cell, was performed on 17 bosses on each rough casting. Ultrasonic transducer selection, initial inspection criteria, and ultrasonic flow detector (UFD) setup parameters were developed for the gray iron castings used in this study. The software were developed for control of the robot and UFD in real time. The software performed two main tasks: emulating the manual operation of the UFD, and evaluating the ultrasonic signatures for detecting subsurface discontinuities. A random lot of 105 castings were tested; the 100 castings that passed were returned to the manufacturer for machining into finished parts and then inspection. The other 5 castings had one boss each with ultrasonic signatures consistent with subsurface discontinuities. The cell was successful in quantifying the ultrasonic echo signatures for the existence of signature characteristics consistent with Go/NoGo criteria developed from simulated defects. Manual inspection showed that no defects in the areas inspected by the automated cell avoided detection in the 100 castings machined into finished parts. Of the 5 bosses found to have subsurface discontinuities, two were verified by manual inspection. The cell correctly classified 1782 of the 1785 bosses (99.832%) inspected.

  8. Foam patterns

    DOE Patents [OSTI]

    Chaudhry, Anil R; Dzugan, Robert; Harrington, Richard M; Neece, Faurice D; Singh, Nipendra P; Westendorf, Travis

    2013-11-26

    A method of creating a foam pattern comprises mixing a polyol component and an isocyanate component to form a liquid mixture. The method further comprises placing a temporary core having a shape corresponding to a desired internal feature in a cavity of a mold and inserting the mixture into the cavity of the mold so that the mixture surrounds a portion of the temporary core. The method optionally further comprises using supporting pins made of foam to support the core in the mold cavity, with such pins becoming integral part of the pattern material simplifying subsequent processing. The method further comprises waiting for a predetermined time sufficient for a reaction from the mixture to form a foam pattern structure corresponding to the cavity of the mold, wherein the foam pattern structure encloses a portion of the temporary core and removing the temporary core from the pattern independent of chemical leaching.

  9. Welding of cast A359/SiC/10p metal matrix composites 

    E-Print Network [OSTI]

    Kothari, Mitul Arvind

    2005-11-01

    Welding of metal matrix composites (MMCs) is an alternative to their mechanical joining, since they are difficult to machine. Published literature in fusion welding of similar composites shows metallurgical problems. This study investigates...

  10. Advanced Melting Technologies: Energy Saving Concepts and Opportunities for the Metal Casting Industry

    SciTech Connect (OSTI)

    None

    2005-11-01

    The study examines current and emerging melting technologies and discusses their technical barriers to scale-up issues and research needed to advance these technologies, improving melting efficiency, lowering metal transfer heat loss, and reducing scrap.

  11. Investigation of fracture mechanical behavior of nodular cast iron and welded joints with parent-material-like weld metal

    SciTech Connect (OSTI)

    Baer, W.; Pusch, G.

    1995-12-31

    The focus of the investigations was the determination of fracture mechanical characteristics and crack resistance curves of the J-Integral and CTOD concept by application of the partial unloading compliance technique and D.C. potential drop technique (four point bend) under static load. The results show a close correlation between crack initiation values as well as crack resistance curves and graphite morphology parameters determined by means of quantitative microstructural analysis where the influence of the matrix (distance of graphite particles) dominates the crack resistance and fracture performance of ferritic nodular cast iron under consideration of the notch effect of graphite particles. SEM in-situ tensile tests showed that due to a beneficial shielding effect of the strength overmatching parent-material-like weld metal (mis-match ratio M = 1.21), cracks positioned directly in the plane of the fusion line did not deviate into the weld metal in spite of its lower toughness compared to that of the parent material. They also showed an unsymmetrical formation of damage in front of the crack tip.

  12. Foam Transport in Porous Media - A Review

    SciTech Connect (OSTI)

    Zhang, Z. F.; Freedman, Vicky L.; Zhong, Lirong

    2009-11-11

    Amendment solutions with or without surfactants have been used to remove contaminants from soil. However, it has drawbacks such that the amendment solution often mobilizes the plume, and its movement is controlled by gravity and preferential flow paths. Foam is an emulsion-like, two-phase system in which gas cells are dispersed in a liquid and separated by thin liquid films called lamellae. Potential advantages of using foams in sub-surface remediation include providing better control on the volume of fluids injected, uniformity of contact, and the ability to contain the migration of contaminant laden liquids. It is expected that foam can serve as a carrier of amendments for vadose zone remediation, e.g., at the Hanford Site. As part of the U.S. Department of Energy’s EM-20 program, a numerical simulation capability will be added to the Subsurface Transport Over Multiple Phases (STOMP) flow simulator. The primary purpose of this document is to review the modeling approaches of foam transport in porous media. However, as an aid to understanding the simulation approaches, some experiments under unsaturated conditions and the processes of foam transport are also reviewed. Foam may be formed when the surfactant concentration is above the critical micelle concentration. There are two main types of foams – the ball foam (microfoam) and the polyhedral foam. The characteristics of bulk foam are described by the properties such as foam quality, texture, stability, density, surface tension, disjoining pressure, etc. Foam has been used to flush contaminants such as metals, organics, and nonaqueous phase liquids from unsaturated soil. Ball foam, or colloidal gas aphrons, reportedly have been used for soil flushing in contaminated site remediation and was found to be more efficient than surfactant solutions on the basis of weight of contaminant removed per gram of surfactant. Experiments also indicate that the polyhedral foam can be used to enhance soil remediation. The transport of foam in porous media is complicated in that the number of lamellae present governs flow characteristics such as viscosity, relative permeability, fluid distribution, and interactions between fluids. Hence, foam is a non-Newtonian fluid. During transport, foam destruction and formation occur. The net result of the two processes determines the foam texture (i.e., bubble density). Some of the foam may be trapped during transport. According to the impacts of the aqueous and gas flow rates, foam flow generally has two regimes – weak and strong foam. There is also a minimum pressure gradient to initiate foam flow and a critical capillary for foam to be sustained. Similar to other fluids, the transport of foam is described by Darcy’s law with the exception that the foam viscosity is variable. Three major approaches to modeling foam transport in porous media are the empirical, semi-empirical, and mechanistic methods. Mechanistic approaches can be complete in principal but may be difficult to obtain reliable parameters, whereas empirical and semi-empirical approaches can be limited by the detail used to describe foam rheology and mobility. Mechanistic approaches include the bubble population-balance model, the network/percolation theory, the catastrophe theory, and the filtration theory. Among these methods, all were developed for modeling polyhedral foam with the exception that the method based on the filtration theory was for the ball foam (microfoam).

  13. Development of Integrated Die Casting Process for Large Thin...

    Broader source: Energy.gov (indexed) [DOE]

    metal only where you need it; minimal yield loss * Die casting no rolling or welding * Die casting scalable to mass production * Compatible with complex geometric...

  14. Strip casting apparatus and method

    DOE Patents [OSTI]

    Williams, Robert S. (Plum, PA); Baker, Donald F. (Hempfield, PA)

    1988-01-01

    Strip casting apparatus including a molten-metal-holding container and a nozzle to deposit molten metal onto a moving chill drum to directly cast continuous metallic strip. The nozzle body includes a slot bounded between a back and a front lip. The slot width exceeds about 20 times the gap distance between the nozzle and the chill drum surface. Preferably, the slot width exceeds 0.5 inch. This method of strip casting minimizes pressure drop, insuring better metal-to-chill-drum contact which promotes heat transfer and results in a better quality metallic strip.

  15. Strip casting apparatus and method

    DOE Patents [OSTI]

    Williams, R.S.; Baker, D.F.

    1988-09-20

    Strip casting apparatus including a molten-metal-holding container and a nozzle to deposit molten metal onto a moving chill drum to directly cast continuous metallic strip. The nozzle body includes a slot bounded between a back and a front lip. The slot width exceeds about 20 times the gap distance between the nozzle and the chill drum surface. Preferably, the slot width exceeds 0.5 inch. This method of strip casting minimizes pressure drop, insuring better metal-to-chill-drum contact which promotes heat transfer and results in a better quality metallic strip. 6 figs.

  16. Cooperation, the Craft Economy, and Metal Technology during the Bronze and Iron Ages in Central Anatolia

    E-Print Network [OSTI]

    Lehner, Joseph William

    2015-01-01

    and copper hardens the metal, alters casting properties, andproduced metal to worked scrap, alloying, casting, andto melt metals and alloys for later casting and working.

  17. Liquid foams of graphene

    E-Print Network [OSTI]

    Alcazar Jorba, Daniel

    2012-01-01

    Liquid foams are dispersions of bubbles in a liquid. Bubbles are stabilized by foaming agents that position at the interface between the gas and the liquid. Most foaming agents, such as the commonly used sodium dodecylsulfate, ...

  18. Development of Steel Foam Materials and Structures

    SciTech Connect (OSTI)

    Kenneth Kremer; Anthony Liszkiewicz; James Adkins

    2004-10-20

    In the past few years there has been a growing interest in lightweight metal foams. Demands for weight reduction, improved fuel efficiency, and increased passenger safety in automobiles now has manufacturers seriously considering the use of metal foams, in contrast to a few years ago, when the same materials would have been ruled out for technical or economical reasons. The objective of this program was to advance the development and use of steel foam materials, by demonstrating the advantages of these novel lightweight materials in selected generic applications. Progress was made in defining materials and process parameters; characterization of physical and mechanical properties; and fabrication and testing of generic steel foam-filled shapes with compositions from 2.5 wt.% to 0.7 wt.% carbon. A means of producing steel foam shapes with uniform long range porosity levels of 50 to 60 percent was demonstrated and verified with NDE methods. Steel foam integrated beams, cylinders and plates were mechanically tested and demonstrated advantages in bend stiffness, bend resistance, and crush energy absorption. Methods of joining by welding, adhesive bonding, and mechanical fastening were investigated. It is important to keep in mind that steel foam is a conventional material in an unconventional form. A substantial amount of physical and mechanical properties are presented throughout the report and in a properties database at the end of the report to support designer's in applying steel foam in unconventional ways.

  19. A comparison of the marginal adaptation of cathode-arc vapor-deposited titanium and cast base metal copings.

    E-Print Network [OSTI]

    Wu, Jean C; Lai, Li-Chung; Sheets, Cherilyn G; Earthman, James; Newcomb, Robert

    2011-01-01

    without use of the lost wax method. 22 The cathode-arcusing the conventional lost wax casting technique and con-The die was dipped into a wax pot (Hotty; Renfert GmbH,

  20. A novel biomimetic approach to the design of high-performance ceramic/metal composites

    E-Print Network [OSTI]

    Launey, Maximilien E.

    2010-01-01

    metals; composites; toughness; strength; freeze casting metal laminates fabricated using  conventional  processing  (e.g. ,  tape  or  slip  casting), 

  1. Nanoporous cobalt foam and a Co/Co(OH)2 coreshell structure for electrochemical applications

    E-Print Network [OSTI]

    Hong, Soon Hyung

    - smelting process,11 and transition metal foams of nickel, copper, cobalt, and Ni­Cu and Ni­Co alloys have nanoporous cobalt foam and its application in a supercapacitor. Pearl- necklace-type carbon nanotube (CNT

  2. The properties of copper foams with negative Poisson's ratio via resonant ultrasound spectroscopy

    E-Print Network [OSTI]

    Lakes, Roderic

    such as flexural rigidity and plane strain fracture toughness [3]. Re- entrant transformation of copper foam the softening point, and cooled. For ductile metal foams, the material is compressed permanently in increments

  3. Energy Consumption of Die Casting Operations

    SciTech Connect (OSTI)

    Jerald Brevick; clark Mount-Campbell; Carroll Mobley

    2004-03-15

    Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption [1]. The obvious major energy requirements are for melting and holding molten alloy in preparation for casting. The proper selection and maintenance of melting and holding equipment are clearly important factors in minimizing energy consumption in die-casting operations [2]. In addition to energy consumption, furnace selection also influences metal loss due to oxidation, metal quality, and maintenance requirements. Other important factors influencing energy consumption in a die-casting facility include geographic location, alloy(s) cast, starting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting machine, related equipment (robots, trim presses), and downstream processing (machining, plating, assembly, etc.). Each of these factors also may influence the casting quality and productivity of a die-casting enterprise. In a die-casting enterprise, decisions regarding these issues are made frequently and are based on a large number of factors. Therefore, it is not surprising that energy consumption can vary significantly from one die-casting enterprise to the next, and within a single enterprise as function of time.

  4. Fillability of Thin-Wall Steel Castings

    SciTech Connect (OSTI)

    Robert C. Voigt; Joseph Bertoletti; Andrew Kaley; Sandi Ricotta; Travis Sunday

    2002-07-30

    The use of steel components is being challenged by lighter nonferrous or cast iron components. The development of techniques for enhancing and ensuring the filability of thin-wall mold cavities is most critical for thinner wall cast steel production. The purpose of this research was to develop thin-wall casting techniques that can be used to reliably produce thin-wall castings from traditional gravity poured sand casting processes. The focus of the research was to enhance the filling behavior to prevent misrunds. Experiments were conducted to investigate the influence of various foundry variables on the filling of thin section steel castings. These variables include casting design, heat transfer, gating design, and metal fluidity. Wall thickness and pouring temperature have the greatest effect on casting fill. As wall thickness increases the volume to surface area of the casting increases, which increases the solidification time, allowing the metal to flow further in thicker sect ions. Pouring time is another significant variable affecting casting fill. Increases or decreases of 20% in the pouring time were found to have a significant effect on the filling of thin-wall production castings. Gating variables, including venting, pouring head height, and mold tilting also significantly affected thin-wall casting fill. Filters offer less turbulent, steadier flow, which is appropriate for thicker castings, but they do not enhance thin-wall casting fill.

  5. Ford Cleveland: Inside-Out Analysis Identifies Energy and Cost Savings Opportunities at Metal Casting Plant; Industrial Technologies Program Metal Casting BestPractices Plant-Wide Assessment Case Study

    SciTech Connect (OSTI)

    Not Available

    2003-09-01

    The Ford Cleveland Casting Plant used results from its plant-wide energy efficiency assessment to identify 16 energy- and cost-saving projects. These projects addressed combustion, compressed air, water, steam, motor drive, and lighting systems. When implemented, the projects should save a total of$3.28 million per year. In addition, two long-term projects were identified that together would represent another$9.5 million in cost savings.

  6. Foam drilling simulator 

    E-Print Network [OSTI]

    Paknejad, Amir Saman

    2007-04-25

    of foam change along the wellbore. Foam physical and thermal properties are strongly affected by pressure and temperature. Many problems associated with field applications still exist, and a precise characterization of the rheological properties...

  7. Cryptography: the cast Cryptography: the cast

    E-Print Network [OSTI]

    Sankaran, Gregory R.

    Cryptography: the cast #12;Cryptography: the cast Alice. . . #12;Cryptography: the cast Alice. . . c John Tenniel 1865 #12;Cryptography: the cast Alice. . . c John Tenniel 1865 wishes to send

  8. Coated foams, preparation, uses and articles

    DOE Patents [OSTI]

    Duchane, D.V.; Barthell, B.L.

    1982-10-21

    Hydrophobic cellular material is coated with a thin hydrophilic polymer skin which stretches tightly over the foam but which does not fill the cells of the foam, thus resulting in a polymer-coated foam structure having a smoothness which was not possible in the prior art. In particular, when the hydrophobic cellular material is a specially chosen hydrophobic polymer foam and is formed into arbitrarily chosen shapes prior to the coating with hydrophilic polymer, inertial confinement fusion (ICF) targets of arbitrary shapes can be produced by subsequently coating the shapes with metal or with any other suitable material. New articles of manufacture are produced, including improved ICF targets, improved integrated circuits, and improved solar reflectors and solar collectors. In the coating method, the cell size of the hydrophobic cellular material, the viscosity of the polymer solution used to coat, and the surface tension of the polymer solution used to coat are all very important to the coating.

  9. Doping of carbon foams for use in energy storage devices

    DOE Patents [OSTI]

    Mayer, Steven T. (San Leandro, CA); Pekala, Richard W. (Pleasant Hill, CA); Morrison, Robert L. (Modesto, CA); Kaschmitter, James L. (Pleasanton, CA)

    1994-01-01

    A polymeric foam precursor, wetted with phosphoric acid, is pyrolyzed in an inert atmosphere to produce an open-cell doped carbon foam, which is utilized as a lithium intercalation anode in a secondary, organic electrolyte battery. Tests were conducted in a cell containing an organic electrolyte and using lithium metal counter and reference electrodes, with the anode located therebetween. Results after charge and discharge cycling, for a total of 6 cycles, indicated a substantial increase in the energy storage capability of the phosphorus doped carbon foam relative to the undoped carbon foam, when used as a rechargeable lithium ion battery.

  10. Doping of carbon foams for use in energy storage devices

    DOE Patents [OSTI]

    Mayer, S.T.; Pekala, R.W.; Morrison, R.L.; Kaschmitter, J.L.

    1994-10-25

    A polymeric foam precursor, wetted with phosphoric acid, is pyrolyzed in an inert atmosphere to produce an open-cell doped carbon foam, which is utilized as a lithium intercalation anode in a secondary, organic electrolyte battery. Tests were conducted in a cell containing an organic electrolyte and using lithium metal counter and reference electrodes, with the anode located there between. Results after charge and discharge cycling, for a total of 6 cycles, indicated a substantial increase in the energy storage capability of the phosphorus doped carbon foam relative to the undoped carbon foam, when used as a rechargeable lithium ion battery. 3 figs.

  11. A comparison of the marginal adaptation of cathode-arc vapor-deposited titanium and cast base metal copings.

    E-Print Network [OSTI]

    Wu, Jean C; Lai, Li-Chung; Sheets, Cherilyn G; Earthman, James; Newcomb, Robert

    2011-01-01

    of Prosthetic Dentistry plasma arc on the cathode surface.arc deposition consists of a titanium cathode material and metal plasma

  12. The industrial ecology of the iron casting industry

    E-Print Network [OSTI]

    Jones, Alissa J. (Alissa Jean)

    2007-01-01

    Metal casting is an energy and materials intensive manufacturing process, which is an important U.S. industry. This study analyzes iron casting, in particular, for possible improvements that will result in greater efficiencies ...

  13. Strip casting with fluxing agent applied to casting roll

    DOE Patents [OSTI]

    Williams, Robert S. (Fairfield, OH); O'Malley, Ronald J. (Miamisburg, OH); Sussman, Richard C. (West Chester, OH)

    1997-01-01

    A strip caster (10) for producing a continuous strip (24) includes a tundish (12) for containing a melt (14), a pair of horizontally disposed water cooled casting rolls (22) and devices (29) for electrostatically coating the outer peripheral chill surfaces (44) of the casting rolls with a powder flux material (56). The casting rolls are juxtaposed relative to one another for forming a pouting basin (18) for receiving the melt through a teeming tube (16) thereby establishing a meniscus (20) between the rolls for forming the strip. The melt is protected from the outside air by a non-oxidizing gas passed through a supply line (28) to a sealing chamber (26). A preferred flux is boron oxide having a melting point of about 550.degree. C. The flux coating enhances wetting of the steel melt to the casting roll and dissolves any metal oxide formed on the roll.

  14. Strip casting with fluxing agent applied to casting roll

    DOE Patents [OSTI]

    Williams, R.S.; O`Malley, R.J.; Sussman, R.C.

    1997-07-29

    A strip caster for producing a continuous strip includes a tundish for containing a melt, a pair of horizontally disposed water cooled casting rolls and devices for electrostatically coating the outer peripheral chill surfaces of the casting rolls with a powder flux material. The casting rolls are juxtaposed relative to one another for forming a pouting basin for receiving the melt through a teeming tube thereby establishing a meniscus between the rolls for forming the strip. The melt is protected from the outside air by a non-oxidizing gas passed through a supply line to a sealing chamber. A preferred flux is boron oxide having a melting point of about 550 C. The flux coating enhances wetting of the steel melt to the casting roll and dissolves any metal oxide formed on the roll. 3 figs.

  15. Electrically conductive rigid polyurethane foam

    DOE Patents [OSTI]

    Neet, Thomas E. (Grandview, MO); Spieker, David A. (Olathe, KS)

    1985-03-19

    A rigid, polyurethane foam comprises about 2-10 weight percent, based on the total foam weight, of a carbon black which is CONDUCTEX CC-40-220 or CONDUCTEX SC, whereby the rigid polyurethane foam is electrically conductive and has essentially the same mechanical properties as the same foam without carbon black added.

  16. Electrically conductive rigid polyurethane foam

    DOE Patents [OSTI]

    Neet, T.E.; Spieker, D.A.

    1983-12-08

    A rigid, moldable polyurethane foam comprises about 2 to 10 weight percent, based on the total foam weight, of a carbon black which is CONDUCTEX CC-40-220 or CONDUCTEX SC, whereby the rigid polyurethane foam is electrically conductive and has essentially the same mechanical properties as the same foam without carbon black added.

  17. Ablation Casting Evaluation for High Volume Structural Castings...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Ablation Casting Evaluation for High Volume Structural Castings Ablation Casting Evaluation for High Volume Structural Castings 2012 DOE Hydrogen and Fuel Cells Program and Vehicle...

  18. Casting methods

    SciTech Connect (OSTI)

    Marsden, Kenneth C.; Meyer, Mitchell K.; Grover, Blair K.; Fielding, Randall S.; Wolfensberger, Billy W.

    2012-12-18

    A casting device includes a covered crucible having a top opening and a bottom orifice, a lid covering the top opening, a stopper rod sealing the bottom orifice, and a reusable mold having at least one chamber, a top end of the chamber being open to and positioned below the bottom orifice and a vacuum tap into the chamber being below the top end of the chamber. A casting method includes charging a crucible with a solid material and covering the crucible, heating the crucible, melting the material, evacuating a chamber of a mold to less than 1 atm absolute through a vacuum tap into the chamber, draining the melted material into the evacuated chamber, solidifying the material in the chamber, and removing the solidified material from the chamber without damaging the chamber.

  19. Understanding foams & foaming D.D. Joseph

    E-Print Network [OSTI]

    Joseph, Daniel D.

    in applications ranging from the transport of cuttings in drilling and the placement of sands in cracks in oil. To keep a foam To appear in the column entitled Signi cant Questions in Fluid Mechanics," in the Journal of Fluids Engineering. 1 #12;CMC CMC Figure 1: Surface tension versus bulk concentration . CMC

  20. Low density microcellular foams

    DOE Patents [OSTI]

    Aubert, J.H.; Clough, R.L.; Curro, J.G.; Quintana, C.A.; Russick, E.M.; Shaw, M.T.

    1985-10-02

    Low density, microporous polymer foams are provided by a process which comprises forming a solution of polymer and a suitable solvent followed by rapid cooling of the solution to form a phase-separated system and freeze the phase-separated system. The phase-separated system comprises a polymer phase and a solvent phase, each of which is substantially continuous within the other. The morphology of the polymer phase prior to and subsequent to freezing determine the morphology of the resultant foam. Both isotropic and anisotropic foams can be produced. If isotropic foams are produced, the polymer and solvent are tailored such that the solution spontaneously phase-separates prior to the point at which any component freezes. The morphology of the resultant polymer phase determines the morphology of the reusltant foam and the morphology of the polymer phase is retained by cooling the system at a rate sufficient to freeze one or both components of the system before a change in morphology can occur. Anisotropic foams are produced by forming a solution of polymer and solvent that will not phase separate prior to freezing of one or both components of the solution. In such a process, the solvent typically freezes before phase separation occurs. The morphology of the resultant frozen two-phase system determines the morphology of the resultant foam. The process involves subjecting the solution to essentially one-dimensional cooling. Foams having a density of less than 0.1 g/cc and a uniform cell size of less than 10 ..mu..m and a volume such that the foams have a length greater than 1 cm are provided.

  1. Low density microcellular foams

    DOE Patents [OSTI]

    Aubert, James H. (Albuquerque, NM); Clough, Roger L. (Albuquerque, NM); Curro, John G. (Placitas, NM); Quintana, Carlos A. (Albuquerque, NM); Russick, Edward M. (Albuquerque, NM); Shaw, Montgomery T. (Mansfield Center, CT)

    1987-01-01

    Low density, microporous polymer foams are provided by a process which comprises forming a solution of polymer and a suitable solvent followed by rapid cooling of the solution to form a phase-separated system and freeze the phase-separated system. The phase-separated system comprises a polymer phase and a solvent phase, each of which is substantially continuous within the other. The morphology of the polymer phase prior to and subsequent to freezing determine the morphology of the resultant foam. Both isotropic and anisotropic foams can be produced. If isotropic foams are produced, the polymer and solvent are tailored such that the solution spontaneously phase-separates prior to the point at which any component freezes. The morphology of the resultant polymer phase determines the morphology of the resultant foam and the morphology of the polymer phase is retained by cooling the system at a rate sufficient to freeze one or both components of the system before a change in morphology can occur. Anisotropic foams are produced by forming a solution of polymer and solvent that will not phase separate prior to freezing of one or both components of the solution. In such a process, the solvent typically freezes before phase separation occurs. The morphology of the resultant frozen two-phase system determines the morphology of the resultant foam. The process involves subjecting the solution to essentially one-dimensional cooling. Means for subjecting such a solvent to one-dimensional cooling are also provided. Foams having a density of less than 0.1 g/cc and a uniform cell size of less than 10 .mu.m and a volume such that the foams have a length greater than 1 cm are provided.

  2. Foam encapsulated targets

    DOE Patents [OSTI]

    Nuckolls, John H. (Livermore, CA); Thiessen, Albert R. (Livermore, CA); Dahlbacka, Glen H. (Livermore, CA)

    1983-01-01

    Foam encapsulated laser-fusion targets wherein a quantity of thermonuclear fuel is embedded in low density, microcellular foam which serves as an electron conduction channel for symmetrical implosion of the fuel by illumination of the target by one or more laser beams. The fuel, such as DT, is contained within a hollow shell constructed of glass, for example, with the foam having a cell size of preferably no greater than 2 .mu.m, a density of 0.065 to 0.6.times.10.sup.3 kg/m.sup.3, and external diameter of less than 200 .mu.m.

  3. Development of Integrated Die Casting Process for Large Thin...

    Broader source: Energy.gov (indexed) [DOE]

    Documents & Publications FY 2008 Progress Report for Lightweighting Materials - 3. Automotive Metals-Cast Advance Patent Waiver W(A)2013-016 CX-008995: Categorical Exclusion...

  4. INTEGRATED DESIGN OF STEEL CASTINGS FOR SERVICE PERFORMANCE

    E-Print Network [OSTI]

    Beckermann, Christoph

    Bellet TMS (The Minerals, Metals & Materials Society), 2006 #12;Casting Simulation (Shrinkage PredictionINTEGRATED DESIGN OF STEEL CASTINGS FOR SERVICE PERFORMANCE Richard. A. Hardin1 , Richard K. Huff2, USA 2 Caterpillar Inc., Champaign, IL 61820, USA Keywords: steel casting, porosity, fatigue life

  5. Method of preparation of removable syntactic foam

    DOE Patents [OSTI]

    Arnold, Jr., Charles (Albuquerque, NM); Derzon, Dora K. (Albuquerque, NM); Nelson, Jill S. (Albuquerque, NM); Rand, Peter B. (Albuquerque, NM)

    1995-01-01

    Easily removable, environmentally safe, low-density, syntactic foams are disclosed which are prepared by mixing insoluble microballoons with a solution of water and/or alcohol-soluble polymer to produce a pourable slurry, optionally vacuum filtering the slurry in varying degrees to remove unwanted solvent and solute polymer, and drying to remove residual solvent. The properties of the foams can be controlled by the concentration and physical properties of the polymer, and by the size and properties of the microballoons. The suggested solute polymers are non-toxic and soluble in environmentally safe solvents such as water or low-molecular weight alcohols. The syntactic foams produced by this process are particularly useful in those applications where ease of removability is beneficial, and could find use in packaging recoverable electronic components, in drilling and mining applications, in building trades, in art works, in the entertainment industry for special effects, in manufacturing as temporary fixtures, in agriculture as temporary supports and containers and for delivery of fertilizer, in medicine as casts and splints, as temporary thermal barriers, as temporary protective covers for fragile objects, as filters for particulate matter, which matter may be easily recovered upon exposure to a solvent, as in-situ valves (for one-time use) which go from maximum to minimum impedance when solvent flows through, and for the automatic opening or closing of spring-loaded, mechanical switches upon exposure to a solvent, among other applications.

  6. Method of preparation of removable syntactic foam

    DOE Patents [OSTI]

    Arnold, C. Jr.; Derzon, D.K.; Nelson, J.S.; Rand, P.B.

    1995-07-11

    Easily removable, environmentally safe, low-density, syntactic foams are disclosed which are prepared by mixing insoluble microballoons with a solution of water and/or alcohol-soluble polymer to produce a pourable slurry, optionally vacuum filtering the slurry in varying degrees to remove unwanted solvent and solute polymer, and drying to remove residual solvent. The properties of the foams can be controlled by the concentration and physical properties of the polymer, and by the size and properties of the microballoons. The suggested solute polymers are non-toxic and soluble in environmentally safe solvents such as water or low-molecular weight alcohols. The syntactic foams produced by this process are particularly useful in those applications where ease of removability is beneficial, and could find use in packaging recoverable electronic components, in drilling and mining applications, in building trades, in art works, in the entertainment industry for special effects, in manufacturing as temporary fixtures, in agriculture as temporary supports and containers and for delivery of fertilizer, in medicine as casts and splints, as temporary thermal barriers, as temporary protective covers for fragile objects, as filters for particulate matter, which matter may be easily recovered upon exposure to a solvent, as in-situ valves (for one-time use) which go from maximum to minimum impedance when solvent flows through, and for the automatic opening or closing of spring-loaded, mechanical switches upon exposure to a solvent, among other applications. 1 fig.

  7. Rigid zeolite containing polyurethane foams

    DOE Patents [OSTI]

    Frost, Charles B. (Livermore, CA)

    1985-01-01

    A closed cell rigid polyurethane foam has been prepared which contains up to about 60% by weight of molecular sieves capable of sorbing molecules with effective critical diameters of up to about 10 .ANG.. The molecular sieve component of the foam can be preloaded with catalysts or with reactive compounds that can be released upon activation of the foam to control and complete crosslinking after the foam is formed. The foam can also be loaded with water or other flame-retarding agents, after completion. Up to about 50% of the weight of the isocyanate component of the foam can be replaced by polyimide resin precursors for incorporation into the final polymeric network.

  8. Rigid zeolite containing polyurethane foams

    DOE Patents [OSTI]

    Frost, C.B.

    1984-05-18

    A closed cell rigid polyurethane foam has been prepared which contains up to about 60% by weight of molecular sieves capable of sorbing molecules with effective critical diameters of up to about 10 A. The molecular sieve component of the foam can be preloaded with catalysts or with reactive compounds that can be released upon activation of the foam to control and complete crosslinking after the foam is formed. The foam can also be loaded with water or other flame-retarding agents, after completion. Up to about 50% of the weight of the isocyanate component of the foam can be replaced by polyimide resin precursors for incorporation into the final polymeric network.

  9. Cast for Mr. Shiffley 

    E-Print Network [OSTI]

    Unknown

    2011-08-17

    A commercial foundry has been established which makes extensive use of fluid beds in the production of heat treated alloy steel castings. The castings are cooled immediately after solidification by fluidizing the mold sand in which they were cast...

  10. Foaming and Antifoaming in Radioactive Waste Pretreatment and Immobilization

    SciTech Connect (OSTI)

    Darsh T. Wasan

    2002-02-20

    Radioactive waste treatment processes usually involve concentration of radionuclides before waste can be immobilized by storing it in stable solid form. Foaming is observed at various stages of waste processing like sludge chemical processing and melter operations. Hence, the objective of this research was to study the mechanisms that produce foaming during nuclear waste treatment, to identify key parameters which aggravate foaming, and to identify effective ways to eliminate or mitigate foaming. Experimental and theoretical investigations of the surface phenomenon, suspension rheology, and bubble generation and interactions that lead to the formation of foam during waste processing were pursued under this EMSP project. Advanced experimental techniques including a novel capillary force balance in conjunction with the combined differential and common interferometry were developed to characterize particle-particle interactions at the foam lamella surfaces as well as inside the foam lamella. Laboratory tests were conducted using a non-radioactive simulant slurry containing high levels of noble metals and mercury similar to the High-Level Waste. We concluded that foaminess of the simulant sludge was due to the presence of colloidal particles such as aluminum, iron, and manganese. We have established the two major mechanisms of formation and stabilization of foams containing such colloidal particles: (1) structural and depletion forces; and (2) steric stabilization due to the adsorbed particles at the surfaces of the foam lamella. Based on this mechanistic understanding of foam generation and stability, an improved antifoam agent was developed by us, since commercial antifoam agents were found to be ineffective in the aggressive physical and chemical environment present in the sludge processing. The improved antifoamer was subsequently tested in a pilot plant at the Savannah River Site (SRS) and was found to be effective. Also, in the SRTC experiment, the irradiated antifoamer appeared to be as effective as nonirradiated antifoamers. Therefore, the results of this research have led to the successful development, demonstration and deployment of the new antifoam in the Defense Waste Processing Facility chemical processing.

  11. Get familiar with CO2 foaming process to produce polymeric foams Research field: Get familiar with CO2 foaming process to produce polymeric foams

    E-Print Network [OSTI]

    Milgram, Paul

    Get familiar with CO2 foaming process to produce polymeric foams Research field: Get familiar with CO2 foaming process to produce polymeric foams Nature of job: Polymeric foams have now been widely, etc. The properties of those foams are directly related with the structure and are therefore dependent

  12. Surfactant monitoring by foam generation

    DOE Patents [OSTI]

    Mullen, Ken I. (Los Alamos, NM)

    1997-01-01

    A device for monitoring the presence or absence of active surfactant or other surface active agents in a solution or flowing stream based on the formation of foam or bubbles is presented. The device detects the formation of foam with a light beam or conductivity measurement. The height or density of the foam can be correlated to the concentration of the active surfactant present.

  13. ITP Metal Casting: Implementation of Metal Casting Best Practices |

    Broader source: Energy.gov (indexed) [DOE]

    AFDC Printable Version Share this resource Send a link to EERE: Alternative Fuels Data Center Home Page to someone by E-mail Share EERE: Alternative Fuels Data Center Home Page on Facebook Tweet about EERE: Alternative Fuels Data Center Home Page on Twitter Bookmark EERE: Alternative Fuels Data Center Homesum_a_epg0_fpd_mmcf_m.xls" ,"Available from WebQuantity of Natural GasAdjustmentsShirleyEnergyTher i nA Guide to TappingWORKof71 HydrogenComputer screenBoilers

  14. Low density microcellular foams

    DOE Patents [OSTI]

    LeMay, James D. (Castro Valley, CA)

    1991-01-01

    Disclosed is a process of producing microcellular foam which comprises the steps of: (a) selecting a multifunctional epoxy oligomer resin; (b) mixing said epoxy resin with a non-reactive diluent to form a resin-diluent mixture; (c) forming a diluent containing cross-linked epoxy gel from said resin-diluent mixture; (d) replacing said diluent with a solvent therefore; (e) replacing said solvent with liquid carbon dioxide; and (f) vaporizing off said liquid carbon dioxide under supercritical conditions, whereby a foam having a density in the range of 35-150 mg/cc and cell diameters less than about 1 .mu.m is produced. Also disclosed are the foams produced by the process.

  15. Low density microcellular foams

    DOE Patents [OSTI]

    LeMay, J.D.

    1991-11-19

    Disclosed is a process of producing microcellular foam which comprises the steps of: (a) selecting a multifunctional epoxy oligomer resin; (b) mixing said epoxy resin with a non-reactive diluent to form a resin-diluent mixture; (c) forming a diluent containing cross-linked epoxy gel from said resin-diluent mixture; (d) replacing said diluent with a solvent therefore; (e) replacing said solvent with liquid carbon dioxide; and (f) vaporizing off said liquid carbon dioxide under supercritical conditions, whereby a foam having a density in the range of 35-150 mg/cc and cell diameters less than about 1 [mu]m is produced. Also disclosed are the foams produced by the process. 8 figures.

  16. Long lasting decontamination foam

    DOE Patents [OSTI]

    Demmer, Ricky L. (Idaho Falls, ID); Peterman, Dean R. (Idaho Falls, ID); Tripp, Julia L. (Pocatello, ID); Cooper, David C. (Idaho Falls, ID); Wright, Karen E. (Idaho Falls, ID)

    2010-12-07

    Compositions and methods for decontaminating surfaces are disclosed. More specifically, compositions and methods for decontamination using a composition capable of generating a long lasting foam are disclosed. Compositions may include a surfactant and gelatin and have a pH of less than about 6. Such compositions may further include affinity-shifting chemicals. Methods may include decontaminating a contaminated surface with a composition or a foam that may include a surfactant and gelatin and have a pH of less than about 6.

  17. Thin sheet casting with electromagnetic pressurization

    DOE Patents [OSTI]

    Walk, Steven R. (Winterport, ME); Slepian, R. Michael (Pittsburgh, PA); Nathenson, Richard D. (Pittsburgh, PA); Williams, Robert S. (Fairfield, OH)

    1991-01-01

    An apparatus, method and system for the casting of thin strips or strips of metal upon a moving chill block that includes an electromagnet located so that molten metal poured from a reservoir onto the chill block passes into the magnetic field produced by the electromagnet. The electromagnet produces a force on the molten metal on said chill block in the direction toward said chill block in order to enhance thermal contact between the molten metal and the chill block.

  18. Foam Processing of Textiles 

    E-Print Network [OSTI]

    Bafford, R. A.; Namboodri, C. G.

    1984-01-01

    Foam processing is an energy-conserving alternative to the conventional wet processing, i.e., dyeing, printing and finishing, of textiles. Where water is ordinarily used as a medium to apply dyes or chemicals to a fabric, up to 75% of the water can...

  19. Method of reducing the green density of a slip cast article

    DOE Patents [OSTI]

    Mangels, John A. (Flat Rock, MI); Dickie, Ray A. (Birmingham, MI)

    1985-01-01

    The method disclosed in this specification is one of reducing the green density of an article cast in a slip casting operation. The article is cast from a casting slip containing silicon metal particles, yttrium containing particles, and a small amount of a fluoride salt which is effective to suppress flocculation of the silicon metal particles by y.sup.+3 ions derived from the yttrium containing particles. The method is characterized by the following step. A small amount of compound which produces a cation which will partly flocculate the particles of silicon metal is added to the casting slip. The small amount of this compound is added so that when the casting slip is slip cast into a casting mold, the partly flocculated particles of silicon will interrupt an otherwise orderly packing of the particles of silicon and particles of yttrium. In this manner, the green density of the slip cast article is reduced and the article may be more easily nitrided.

  20. Bioinspired Design : : Magnetic Freeze Casting

    E-Print Network [OSTI]

    Porter, Michael Martin

    2014-01-01

    30 CHAPTER 3: FREEZE CASTING: A94 CHAPTER 5: MAGNETIC FREEZE CASTING INSPIRED BY98 5.2.1. Magnetic freeze casting

  1. Arc Casting Intermetallic Alloy (Materials Preparation Center)

    SciTech Connect (OSTI)

    2010-01-01

    Arc casting of intermetallic (La-Ni-Sn) AB5 alloy used for metal hydride hydrogen storage. Upon solidification the Sn is partially rejected and increases in concentration in the remaining liquid. Upon completing solidification there is a great deal of internal stress in the ingot. As the ingot cools further the stress is relieved. This material was cast at the Ames Laboratorys Materials Preparation Center http://www.mpc.ameslab.gov

  2. Generalized correlation for foam flow in tubes 

    E-Print Network [OSTI]

    Cotter, Carol Lynnette

    1996-01-01

    with respect to foam in the laminar flow region. A semi-automated system to collect pressure drop-flow rate data for gas in liquid foams was constructed in which foam is created by a foam generator and the pressure drop resulting from the foam flow is measured...

  3. Low density microcellular foams

    DOE Patents [OSTI]

    LeMay, James D. (Castro Valley, CA)

    1992-01-01

    Disclosed is a process of producing microcellular from which comprises the steps of: (a) selecting a multifunctional epoxy oligomer resin; (b) mixing said epoxy resin with a non-reactive diluent to form a resin-diluent mixture; (c) forming a diluent containing cross-linked epoxy gel from said resin-diluent mixture; (d) replacing said diluent with a solvent therefore; (e) replacing said solvent with liquid carbon dioxide; and (f) vaporizing off said liquid carbon dioxide under supercritical conditions, whereby a foam having a density in the range of 35-150 mg/cc and cell diameters less than about 1 .mu.m is produced. Also disclosed are the foams produced by the process.

  4. Method and apparatus for improving the insulating properties of closed cell foam

    DOE Patents [OSTI]

    Glicksman, Leon R. (Lynnfield, MA); Lanciani, Arlene J. (Sterling, MA)

    1991-04-23

    A filler of non-metallic, light transparent material is formed into particles or flakes and coated with opaque material and dispersed in closed cell foam to reduce overall thermal conductivity and, specifically, to reduce radiation heat transfer.

  5. Effects of the Exposure to Corrosive Salts on the Frictional Behavior of Gray Cast Iron and a Titanium-Based Metal Matrix Composite

    SciTech Connect (OSTI)

    Blau, Peter Julian; Truhan, Jr., John J; Kenik, Edward A

    2007-01-01

    The introduction of increasingly aggressive road-deicing chemicals has created significant and costly corrosion problems for the trucking industry. From a tribological perspective, corrosion of the sliding surfaces of brakes after exposure to road salts can create oxide scales on the surfaces that affect friction. This paper describes experiments on the effects of exposure to sodium chloride and magnesium chloride sprays on the transient frictional behavior of cast iron and a titanium-based composite sliding against a commercial brake lining material. Corrosion scales on cast iron initially act as abrasive third-bodies, then they become crushed, spread out, and behave as a solid lubricant. The composition and subsurface microstructures of the corrosion products on the cast iron were analyzed. Owing to its greater corrosion resistance, the titanium composite remained scale-free and its frictional response was markedly different. No corrosion scales were formed on the titanium composite after aggressive exposure to salts; however, a reduction in friction was still observed. Unlike the crystalline sodium chloride deposits that tended to remain dry, hygroscopic magnesium chloride deposits absorbed ambient moisture from the air, liquefied, and retained a persistent lubricating effect on the titanium surfaces.

  6. Method to prevent/mitigate steam explosions in casting pits

    DOE Patents [OSTI]

    Taleyarkhan, R.P.

    1996-12-24

    Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water. 3 figs.

  7. Method to prevent/mitigate steam explosions in casting pits

    DOE Patents [OSTI]

    Taleyarkhan, Rusi P. (Knoxville, TN)

    1996-01-01

    Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water.

  8. Liquid Foams and K. Brakke

    E-Print Network [OSTI]

    Brakke, Ken

    coarsening with time due to gas diffusion, its elastic and plastic properties, and the drainage of liquid-static properties. However, this is only part of a wider subject: dynamic effects remain as a considerable challenge]), they began to build a systematic theory of foam properties. The recent Physics of Foams [8] is a broad

  9. High temperature lightweight foamed cements

    DOE Patents [OSTI]

    Sugama, Toshifumi (Mastic Beach, NY)

    1989-01-01

    Cement slurries are disclosed which are suitable for use in geothermal wells since they can withstand high temperatures and high pressures. The formulation consists of cement, silica flour, water, a retarder, a foaming agent, a foam stabilizer, and a reinforcing agent. A process for producing these cements is also disclosed.

  10. High temperature lightweight foamed cements

    DOE Patents [OSTI]

    Sugama, Toshifumi.

    1989-10-03

    Cement slurries are disclosed which are suitable for use in geothermal wells since they can withstand high temperatures and high pressures. The formulation consists of cement, silica flour, water, a retarder, a foaming agent, a foam stabilizer, and a reinforcing agent. A process for producing these cements is also disclosed. 3 figs.

  11. Mechanical Characterization of Rigid Polyurethane Foams.

    SciTech Connect (OSTI)

    Lu, Wei-Yang

    2014-12-01

    Foam materials are used to protect sensitive components from impact loading. In order to predict and simulate the foam performance under various loading conditions, a validated foam model is needed and the mechanical properties of foams need to be characterized. Uniaxial compression and tension tests were conducted for different densities of foams under various temperatures and loading rates. Crush stress, tensile strength, and elastic modulus were obtained. A newly developed confined compression experiment provided data for investigating the foam flow direction. A biaxial tension experiment was also developed to explore the damage surface of a rigid polyurethane foam.

  12. Process and apparatus for casting multiple silicon wafer articles

    DOE Patents [OSTI]

    Nanis, Leonard (Palo Alto, CA)

    1992-05-05

    Method and apparatus of casting silicon produced by the reaction between SiF.sub.4 and an alkaline earth metal into thin wafer-shaped articles suitable for solar cell fabrication.

  13. Multifunctional Corrosion-resistant Foamed Well Cement Composites...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Multifunctional Corrosion-resistant Foamed Well Cement Composites Multifunctional Corrosion-resistant Foamed Well Cement Composites Multifunctional Corrosion-resistant Foamed Well...

  14. Carbon foam characterization tensile evaluation of carbon foam ligaments 

    E-Print Network [OSTI]

    Verdugo Rodriguez, Rogelio Alberto

    2004-09-30

    of the carbon foam ligaments (RVC) could be described with a one-population distribution, it is found that a two-population Weibull distribution is necessary to describe the distribution of strength of the SiC coated ligaments....

  15. Method and apparatus for planar drag strip casting

    DOE Patents [OSTI]

    Powell, John C. (Pittsburgh, PA); Campbell, Steven L. (Middletown, OH)

    1991-01-01

    The present invention is directed to an improved process and apparatus for strip casting. The combination of a planar flow casting nozzle positioned back from the top dead center position with an attached nozzle extension, provides an increased level of casting control and quality. The nozzle extension provides a means of containing the molten pool above the rotating substrate to increase the control of molten metal at the edges of the strip and increase the range of coating thicknesses which may be produced. The level of molten metal in the containment means is regulated to be above the level of melt supplying the casting nozzle which produces a condition of planar drag flow with the casting substrate prior to solidification.

  16. Method and apparatus for planar drag strip casting

    DOE Patents [OSTI]

    Powell, J.C.; Campbell, S.L.

    1991-11-12

    The present invention is directed to an improved process and apparatus for strip casting. The combination of a planar flow casting nozzle positioned back from the top dead center position with an attached nozzle extension, provides an increased level of casting control and quality. The nozzle extension provides a means of containing the molten pool above the rotating substrate to increase the control of molten metal at the edges of the strip and increase the range of coating thicknesses which may be produced. The level of molten metal in the containment means is regulated to be above the level of melt supplying the casting nozzle which produces a condition of planar drag flow with the casting substrate prior to solidification. 5 figures.

  17. Hickey, W8206, all casts Hickey, W8206, all casts, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8206, all casts Hickey, W8206, all casts, page 1 #12;Hickey, W8206, all casts Hickey, W8206, all casts, page 2 #12;Hickey, W8206, all casts Hickey, W8206, all casts, page 3 #12;Hickey, W8206, all casts Hickey, W8206, all casts, page 4 #12;Hickey, W8206, all casts Hickey, W8206, all casts, page

  18. High temperature adhesive silicone foam composition, foam generating system and method of generating foam

    DOE Patents [OSTI]

    Mead, Judith W. (Peralta, NM); Montoya, Orelio J. (Albuquerque, NM); Rand, Peter B. (Albuquerque, NM); Willan, Vernon O. (Albuquerque, NM)

    1984-01-01

    Access to a space is impeded by generation of a sticky foam from a silicone polymer and a low boiling solvent such as a halogenated hydrocarbon. In a preferred aspect, the formulation is polydimethylsiloxane gel mixed with F502 Freon as a solvent and blowing agent, and pressurized with CO.sub.2 in a vessel to about 250 PSI, whereby when the vessel is opened, a sticky and solvent resistant foam is deployed. The foam is deployable, over a wide range of temperatures, adhering to wet surfaces as well as dry, is stable over long periods of time and does not propagate flame or lose adhesive properties during an externally supported burn.

  19. Low density carbonized composite foams

    DOE Patents [OSTI]

    Kong, Fung-Ming (Pleasanton, CA)

    1991-01-01

    A carbonized composite foam having a density less than about 50 mg/cm.sup.3 and individual cell sizes no greater than about 1 .mu.m in diameter is described, and the process of making it.

  20. Process for making carbon foam

    DOE Patents [OSTI]

    Klett, James W. (Knoxville, TN)

    2000-01-01

    The process obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.

  1. Supercapacitors based on carbon foams

    DOE Patents [OSTI]

    Kaschmitter, James L. (6291 Alisal St., Pleasanton, CA 94566); Mayer, Steven T. (16026 Selborne Dr., San Leandro, CA 94578); Pekala, Richard W. (802 Cliffside Dr., Pleasant Hill, CA 94523)

    1993-01-01

    A high energy density capacitor incorporating a variety of carbon foam electrodes is described. The foams, derived from the pyrolysis of resorcinol-formaldehyde and related polymers, are high density (0.1 g/cc-1.0 g/cc) electrically conductive and have high surface areas (400 m.sup.2 /g-1000 m.sup.2 /g). Capacitances on the order of several tens of farad per gram of electrode are achieved.

  2. Supercapacitors based on carbon foams

    SciTech Connect (OSTI)

    Kaschmitter, J.L.; Mayer, S.T.; Pekala, R.W.

    1993-11-09

    A high energy density capacitor incorporating a variety of carbon foam electrodes is described. The foams, derived from the pyrolysis of resorcinol-formaldehyde and related polymers, are high density (0.1 g/cc-1.0 g/cc) electrically conductive and have high surface areas (400 m[sup 2]/g-1000 m[sup 2]/g). Capacitances on the order of several tens of farad per gram of electrode are achieved. 9 figures.

  3. Constant permeability of (Fe{sub 0.75}B{sub 0.20}Si{sub 0.05}){sub 96}Nb{sub 4} bulk metallic glass prepared by B{sub 2}O{sub 3} flux melting and Cu-mold casting

    SciTech Connect (OSTI)

    Bitoh, T.; Shibata, D. [Department of Machine Intelligence and Systems Engineering, Faculty of Systems Science and Technology, Akita Prefectural University, Yurihonjo 015-0055 (Japan)

    2009-04-01

    The effect of B{sub 2}O{sub 3} flux melting on the soft magnetic properties of (Fe{sub 0.75}B{sub 0.20}Si{sub 0.05}){sub 96}Nb{sub 4} bulk metallic glass prepared by casting has been investigated. Ring-shaped bulk specimens that were prepared by B{sub 2}O{sub 3} flux melting and Cu-mold casting (fluxed specimens) show a flat hysteresis curve, indicating a good linear relationship between the magnetic induction and the applied magnetic field. Although the permeability of the fluxed specimens is lower than that of the specimens prepared by conventional Cu-mold casting by one order of magnitude, their coercivities are almost same. These results show that it is possible to develop a new soft magnetic material that exhibits constant permeability with low core loss.

  4. Optimization and Stabilization of LBM Free Surface Flow Simulations using Adaptive

    E-Print Network [OSTI]

    casting or the cre- ation of metal foams involving the accurate tracking of a liquid gas interface. Also

  5. Flow of fracturing foams in vertical, horizontal and inclined pipes 

    E-Print Network [OSTI]

    Krindinti, Kshipraprasad H

    2002-01-01

    Foams are complex mixtures of a gas and a liquid, with the latter being the continuous phase. The rheological properties of foams are strongly influenced by parameters like temperature, absolute pressure, foam quality, texture, foam-channel wall...

  6. MECHANISTIC STUDIES OF IMPROVED FOAM EOR PROCESSES

    SciTech Connect (OSTI)

    William R. Rossen

    2005-03-16

    The objective of this research is to widen the application of foam to enhanced oil recovery (EOR) by investigating fundamental mechanisms of foams in porous media. This research is to lay the groundwork for more-applied research on foams for improved sweep efficiency in miscible gas, steam and surfactant-based EOR. Task 1 investigates the pore-scale interactions between foam bubbles and polymer molecules. Task 2 examines the mechanisms of gas trapping, and interaction between gas trapping and foam effectiveness. Task 3 investigates mechanisms of foam generation in porous media.

  7. MECHANISTIC STUDIES OF IMPROVED FOAM EOR PROCESSES

    SciTech Connect (OSTI)

    William R. Rossen

    2005-01-05

    The objective of this research is to widen the application of foam to enhanced oil recovery (EOR) by investigating fundamental mechanisms of foams in porous media. This research will lay the groundwork for more applied research on foams for improved sweep efficiency in miscible gas, steam and surfactant-based EOR. Task 1 investigates the pore-scale interactions between foam bubbles and polymer molecules. Task 2 examines the mechanisms of gas trapping, and interaction between gas trapping and foam effectiveness. Task 3 investigates mechanisms of foam generation in porous media.

  8. Biopolymer foams - Relationship between material characteristics and foaming behavior of cellulose based foams

    SciTech Connect (OSTI)

    Rapp, F., E-mail: florian.rapp@ict.fraunhofer.de, E-mail: anja.schneider@ict.fraunhofer.de; Schneider, A., E-mail: florian.rapp@ict.fraunhofer.de, E-mail: anja.schneider@ict.fraunhofer.de [Fraunhofer Institute for Chemical Technology ICT (Germany); Elsner, P., E-mail: peter.elsner@ict.fraunhofer.de [Fraunhofer Institute for Chemical Technology ICT, Germany and Karlsruhe Institute of Technology KIT (Germany)

    2014-05-15

    Biopolymers are becoming increasingly important to both industry and consumers. With regard to waste management, CO{sub 2} balance and the conservation of petrochemical resources, increasing efforts are being made to replace standard plastics with bio-based polymers. Nowadays biopolymers can be built for example of cellulose, lactic acid, starch, lignin or bio mass. The paper will present material properties of selected cellulose based polymers (cellulose propionate [CP], cellulose acetate butyrate [CAB]) and corresponding processing conditions for particle foams as well as characterization of produced parts. Special focus is given to the raw material properties by analyzing thermal behavior (differential scanning calorimetry), melt strength (Rheotens test) and molecular weight distribution (gel-permeation chromatography). These results will be correlated with the foaming behavior in a continuous extrusion process with physical blowing agents and underwater pelletizer. Process set-up regarding particle foam technology, including extrusion foaming and pre-foaming, will be shown. The characteristics of the resulting foam beads will be analyzed regarding part density, cell morphology and geometry. The molded parts will be tested on thermal conductivity as well as compression behavior (E-modulus, compression strength)

  9. Spall behavior of cast iron with varying microstructures

    SciTech Connect (OSTI)

    Plume, Gifford; Rousseau, Carl-Ernst, E-mail: rousseau@uri.edu [Mechanical Engineering, University of Rhode Island, 92 Upper College Rd., Kingston, Rhode Island 02881 (United States)

    2014-07-21

    The spall strength of cast iron with varying microstructures has been investigated using plate impact at moderate speed. Stress history measurements were made with manganin stress gauges embedded between the back face of the specimen and a low impedance polycarbonate backing. Five separate cast irons were tested. Four of these consisted of gray cast iron with graphite in flake form, with three classified as Type VII A2 and the fourth containing a bimodal distribution of Types VII A4 and VII D8. The fifth casting consisted of ductile cast iron with graphite in nodular form, classified as Type I, size class 5. The spall strength for the Type VII A2 gray cast irons varied between 40 and 370?MPa, and that of the additional gray cast iron, between 410 and 490?MPa. The spall strength of the ductile cast iron fell within the range of 0.94–1.2?GPa. It is shown that the spall strength is linked to the damage level at the spall plane, where an increased level of tensile stress is required to generate higher levels of damage. Post mortem analysis was performed on the recovered samples, revealing the graphite phase to be the primary factor governing the spall fracture of cast irons, where crack nucleation is directly correlated to the debonding of graphite from the metal matrix. The average length of graphite found within a casting is linked to the material's strength, where strength increases as a function of decreasing length. The morphology and mean free path of graphite precipitates further govern the subsequent coalescence of initiated cracks to form a complete fracture plane. In cases where graphite spacing is large, increased energy level is required to complete the fracture process. A secondary factor governing the spall fracture of cast irons has also been linked to the microstructure of the metal matrix, with pearlite yielding higher spall strengths than free ferrite.

  10. Analysis of Heat Transfer in Metal Hydride Based Hydrogen Separation

    SciTech Connect (OSTI)

    Fleming, W.H. Jr.

    1999-10-20

    This thesis presents a transient heat transfer analysis to model the heat transfer in the Pd/k packed column, and the impact of adding metallic foam.

  11. Approved by CAST Council CAST Learning Technology Advisory Committee

    E-Print Network [OSTI]

    Branoff, Theodore J.

    Approved by CAST Council 12/3/04 CAST Learning Technology Advisory Committee Provost John Presley and security matters. Other probable functions that may be the purview of a CAST Technology Committee would be to advise the Dean on long term planning for technology; periodically review and suggest revisions to CAST

  12. Volume Ray Casting Neslisah Torosdagli

    E-Print Network [OSTI]

    Pattanaik, Sumanta N.

    Volume Ray Casting Neslisah Torosdagli #12;Overview · Light Transfer Optical Models · Math behind Direct Volume Ray Casting · Demonstration · Transfer Functions · Details of our Application · References #12;What is Volume Ray Casting? · Volume Ray Casting is construction of 3D volume using stack of 2D

  13. Experimental characterization of foam drainage and stability 

    E-Print Network [OSTI]

    Sheth, Vikas Rameshchandra

    1993-01-01

    A novel experimental procedure to characterize the stability of foams is established. The procedure involves the unsteady state drainage of liquid from a stationary foam due to an applied pressure difference (forced drainage)- Unlike other bulk...

  14. Assessment of Oxidation in Carbon Foam 

    E-Print Network [OSTI]

    Lee, Seung Min

    2010-07-14

    Carbon foams exhibit numerous unique properties which are attractive for light weight applications such as aircraft and spacecraft as a tailorable material. Carbon foams, when exposed to air, oxidize at temperatures as low ...

  15. Math of Popping Bubbles in a Foam

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Math of Popping Bubbles in a Foam Math of Popping Bubbles in a Foam Berkeley Lab researchers mathematically describe the complex evolution and disappearance of foamy bubbles May 9,...

  16. Optimization of Squeeze Casting for Aluminum Alloy Parts

    SciTech Connect (OSTI)

    David Schwam; John F. Wallace; Qingming Chang; Yulong Zhu

    2002-07-30

    This study was initiated with the installation of a new production size UBE 350 Ton VSC Squeeze Casting system in the Metal Casting Laboratory at Case Western University. A Lindberg 75k W electrical melting furnace was installed alongside. The challenge of installation and operation of such industrial-size equipment in an academic environment was met successfully. Subsequently, a Sterling oil die heater and a Visi-Track shot monitoring system were added. A significant number of inserts were designed and fabricated over the span of the project, primarily for squeeze casting different configurations of test bars and plates. A spiral ''ribbon insert'' for evaluation of molten metal fluidity was also fabricated. These inserts were used to generate a broad range of processing conditions and determine their effect on the quality of the squeeze cast parts. This investigation has studied the influence of the various casting variables on the quality of indirect squeeze castings primarily of aluminum alloys. The variables studied include gating design, fill time and fill patter, metal pressure and die temperature variations. The quality of the die casting was assessed by an analysis of both their surface condition and internal soundness. The primary metal tested was an aluminum 356 alloy. In addition to determining the effect of these casting variables on casting quality as measured by a flat plate die of various thickness, a number of test bar inserts with different gating designs have been inserted in the squeeze casting machine. The mechanical properties of these test bars produced under different squeeze casting conditions were measured and reported. The investigation of the resulting properties also included an analysis of the microstructure of the squeeze castings and the effect of the various structural constituents on the resulting properties. The main conclusions from this investigation are as follows: The ingate size and shape are very important since it must remain open until the casting is solidified and pressure is maintained on the solidifying casting. Fanned gates, particularly on the smaller section castings avoid jetting effects at the ingate end. The fan type ingate helps accomplish a rapid fill without high velocities. The molten metal has to fill the cavity before localized solidification occurs. This is best accomplished with a larger ingate to attain rapid filling without excessive velocity or jetting that occurs at high metal velocities. Straight gates are prone to case jetting of the metal stream even a low velocities. Fanned gates allow use of higher fill velocity without excessive jetting. A higher metal pressure provides a more complete fill of the die including improved compensation for solidification shrinkage. With the proper filling pattern, ingates, overflows and die temperature for a given die, very good tensile properties can be attained in squeeze casting. In general, the smaller squeeze castings require higher die temperatures. Computer models using the UES Procast and MagmaSoft finite element software can, after suitable adjustments, predict the flow pattern in the die cavity.

  17. Mechanical probing of liquid foam aging

    E-Print Network [OSTI]

    Isabelle Cantat; Olivier Pitois

    2006-09-19

    We present experimental results on the Stokes experiment performed in a 3D dry liquid foam. The system is used as a rheometric tool : from the force exerted on a 1cm glass bead, plunged at controlled velocity in the foam in a quasi static regime, local foam properties are probed around the sphere. With this original and simple technique, we show the possibility of measuring the foam shear modulus, the gravity drainage rate and the evolution of the bubble size during coarsening.

  18. Method of casting aerogels

    DOE Patents [OSTI]

    Poco, John F. (Livermore, CA)

    1993-01-01

    The invention describes a method for making monolithic castings of transparent silica aerogel with densities in the range from 0.001 g/cm.sup.3 to 0.6 g/cm.sup.3. Various shapes of aerogels are cast in flexible polymer molds which facilitate removal and eliminate irregular surfaces. Mold dimensions are preselected to account for shrinkage of alcogel which occurs during the drying step of supercritical extraction of solvent.

  19. Method of casting aerogels

    DOE Patents [OSTI]

    Poco, J.F.

    1993-09-07

    The invention describes a method for making monolithic castings of transparent silica aerogel with densities in the range from 0.001 g/cm[sup 3] to 0.6 g/cm[sup 3]. Various shapes of aerogels are cast in flexible polymer molds which facilitate removal and eliminate irregular surfaces. Mold dimensions are preselected to account for shrinkage of aerogel which occurs during the drying step of supercritical extraction of solvent. 2 figures.

  20. Foam vessel for cryogenic fluid storage

    DOE Patents [OSTI]

    Spear, Jonathan D (San Francisco, CA)

    2011-07-05

    Cryogenic storage and separator vessels made of polyolefin foams are disclosed, as are methods of storing and separating cryogenic fluids and fluid mixtures using these vessels. In one embodiment, the polyolefin foams may be cross-linked, closed-cell polyethylene foams with a density of from about 2 pounds per cubic foot to a density of about 4 pounds per cubic foot.

  1. Highly concentrated foam formulation for blast mitigation

    DOE Patents [OSTI]

    Tucker, Mark D. (Albuquerque, NM); Gao, Huizhen (Albuquerque, NM)

    2010-12-14

    A highly concentrated foam formulation for blast suppression and dispersion mitigation for use in responding to a terrorism incident involving a radiological dispersion device. The foam formulation is more concentrated and more stable than the current blast suppression foam (AFC-380), which reduces the logistics burden on the user.

  2. Method for making thin carbon foam electrodes

    DOE Patents [OSTI]

    Pekala, R.W.; Mayer, S.T.; Kaschmitter, J.L.; Morrison, R.L.

    1999-08-03

    A method for fabricating thin, flat carbon electrodes by infiltrating highly porous carbon papers, membranes, felts, metal fibers/powders, or fabrics with an appropriate carbon foam precursor material is disclosed. The infiltrated carbon paper, for example, is then cured to form a gel-saturated carbon paper, which is subsequently dried and pyrolyzed to form a thin sheet of porous carbon. The material readily stays flat and flexible during curing and pyrolyzing to form thin sheets. Precursor materials include polyacrylonitrile (PAN), polymethylacrylonitrile (PMAN), resorcinol/formaldehyde, catechol/formaldehyde, phenol/formaldehyde, etc., or mixtures thereof. These thin films are ideal for use as high power and energy electrodes in batteries, capacitors, and fuel cells, and are potentially useful for capacitive deionization, filtration and catalysis.

  3. Method for making thin carbon foam electrodes

    DOE Patents [OSTI]

    Pekala, Richard W. (Pleasant Hill, CA); Mayer, Steven T. (San Leandro, CA); Kaschmitter, James L. (Pleasanton, CA); Morrison, Robert L. (Modesto, CA)

    1999-01-01

    A method for fabricating thin, flat carbon electrodes by infiltrating highly porous carbon papers, membranes, felts, metal fibers/powders, or fabrics with an appropriate carbon foam precursor material. The infiltrated carbon paper, for example, is then cured to form a gel-saturated carbon paper, which is subsequently dried and pyrolyzed to form a thin sheet of porous carbon. The material readily stays flat and flexible during curing and pyrolyzing to form thin sheets. Precursor materials include polyacrylonitrile (PAN), polymethylacrylonitrile (PMAN), resorcinol/formaldehyde, catechol/formaldehyde, phenol/formaldehyde, etc., or mixtures thereof. These thin films are ideal for use as high power and energy electrodes in batteries, capacitors, and fuel cells, and are potentially useful for capacitive deionization, filtration and catalysis.

  4. Salvaged castings and methods of salvaging castings with defective cast cooling bumps

    DOE Patents [OSTI]

    Johnson, Robert Alan (Simpsonville, SC); Schaeffer, Jon Conrad (Greenville, SC); Lee, Ching-Pang (Cincinnati, OH); Abuaf, Nesim (Lincoln City, OR); Hasz, Wayne Charles (Pownal, VT)

    2002-01-01

    Castings for gas turbine parts exposed on one side to a high-temperature fluid medium have cast-in bumps on an opposite cooling surface side to enhance heat transfer. Areas on the cooling surface having defectively cast bumps, i.e., missing or partially formed bumps during casting, are coated with a braze alloy and cooling enhancement material to salvage the part.

  5. Heat exchanger using graphite foam

    DOE Patents [OSTI]

    Campagna, Michael Joseph; Callas, James John

    2012-09-25

    A heat exchanger is disclosed. The heat exchanger may have an inlet configured to receive a first fluid and an outlet configured to discharge the first fluid. The heat exchanger may further have at least one passageway configured to conduct the first fluid from the inlet to the outlet. The at least one passageway may be composed of a graphite foam and a layer of graphite material on the exterior of the graphite foam. The layer of graphite material may form at least a partial barrier between the first fluid and a second fluid external to the at least one passageway.

  6. Modeling of Reoxidation Inclusion Formation During Filling of Steel Castings

    E-Print Network [OSTI]

    Beckermann, Christoph

    larger inclusions entering the mold cavity from the ladle, and they can also be born on the metal free of the resulting defect areas with weld metal. Inclusions that remain in the casting adversely affect machining inclusions, which form when deoxidized steel comes into contact with oxygen during mold filling, make up

  7. Method of forming a continuous polymeric skin on a cellular foam material

    DOE Patents [OSTI]

    Duchane, David V. (Los Alamos, NM); Barthell, Barry L. (Los Alamos, NM)

    1985-01-01

    Hydrophobic cellular material is coated with a thin hydrophilic polymer skin which stretches tightly over the outer surface of the foam but which does not fill the cells of the foam, thus resulting in a polymer-coated foam structure having a smoothness which was not possible in the prior art. In particular, when the hydrophobic cellular material is a specially chosen hydrophobic polymer foam and is formed into arbitrarily chosen shapes prior to the coating with hydrophilic polymer, inertial confinement fusion (ICF) targets of arbitrary shapes can be produced by subsequently coating the shapes with metal or with any other suitable material. New articles of manufacture are produced, including improved ICF targets, improved integrated circuits, and improved solar reflectors and solar collectors. In the coating method, the cell size of the hydrophobic cellular material, the viscosity of the polymer solution used to coat, and the surface tensin of the polymer solution used to coat are all very important to the coating.

  8. Method of making a cyanate ester foam

    DOE Patents [OSTI]

    Celina, Mathias C.; Giron, Nicholas Henry

    2014-08-05

    A cyanate ester resin mixture with at least one cyanate ester resin, an isocyanate foaming resin, other co-curatives such as polyol or epoxy compounds, a surfactant, and a catalyst/water can react to form a foaming resin that can be cured at a temperature greater than 50.degree. C. to form a cyanate ester foam. The cyanate ester foam can be heated to a temperature greater than 400.degree. C. in a non-oxidative atmosphere to provide a carbonaceous char foam.

  9. Low density, microcellular foams, preparation, and articles

    DOE Patents [OSTI]

    Young, Ainslie T. (Los Alamos, NM); Marsters, Robert G. (Jemez Springs, NM); Moreno, Dawn K. (Espanola, NM)

    1984-01-01

    A microcellular low density foam of poly(4-methyl-1-pentene) which is particularly useful for forming targets for inertial confinement fusion has been developed. Articles made from the foam have been machined to tolerances of 0.0001 inch, although the densities of the fragile foam are low (about 10 to about 100 mg/cc) and the cell sizes are small (about 10 to about 30 .mu.m). Methods for forming the foam and articles are given; and the yield strength of the foam of the invention is higher than was obtained in other structures of this same material.

  10. Low density, microcellular foams, preparation, and articles

    DOE Patents [OSTI]

    Young, A.T.

    1982-03-03

    A microcellular low-density foam of poly(4-methyl-1-pentene) particularly useful for forming targets for inertial confinement fusion has been developed. Articles made from the foam have been machined to tolerances of 0.0001 inch, although the densities of the fragile foam are low (about 10 to about 100 mg/cc) and the cell sizes are small (about 10 to about 30 ..mu..m). Methods for forming the foam and articles are given. The yield strength of the foam of the invention is higher than was obtained in other structures of this same material.

  11. The Gendering of Film and Television Casting

    E-Print Network [OSTI]

    Hill, Erin

    2011-01-01

    by Erin Hill contents Why did casting, which in its presentbecame interested in casting, a female- dominated professionindustry, after observing the casting process carried out at

  12. Combination nickel foam expanded nickel screen electrical connection supports for solid oxide fuel cells

    DOE Patents [OSTI]

    Draper, Robert; Prevish, Thomas; Bronson, Angela; George, Raymond A.

    2007-01-02

    A solid oxide fuel assembly is made, wherein rows (14, 25) of fuel cells (17, 19, 21, 27, 29, 31), each having an outer interconnection (20) and an outer electrode (32), are disposed next to each other with corrugated, electrically conducting expanded metal mesh member (22) between each row of cells, the corrugated mesh (22) having top crown portions and bottom portions, where the top crown portion (40) have a top bonded open cell nickel foam (51) which contacts outer interconnections (20) of the fuel cells, said mesh and nickel foam electrically connecting each row of fuel cells, and where there are no more metal felt connections between any fuel cells.

  13. Twin-belt continuous caster with containment and cooling of the exiting cast product for enabling high-speed casting of molten-center product

    DOE Patents [OSTI]

    Dykes, Charles D. (303 Shore Rd., Milton, VT); Daniel, Sabah S. (303 Shore Rd., Pittsburgh, PA); Wood, J. F. Barry (303 Shore Rd., Burlington, VT 05401)

    1990-02-20

    In continuously casting molten metal into cast product by a twin-belt machine, it is desirable to achieve dramatic increases in speed (linear feet per minute) at which cast product exits the machine, particularly in installations where steel cast product is intended to feed a downstream regular rolling mill (as distinct from a planetary mill) operating in tandem with the twin-belt caster. Such high-speed casting produces product with a relatively thin shell and molten interior, and the shell tends to bulge outwardly due to metallostatic head pressure of the molten center. A number of cooperative features enable high-speed, twin-belt casting: (1) Each casting belt is slidably supported adjacent to the caster exit pulley for bulge control and enhanced cooling of cast product. (2) Lateral skew steering of each belt provides an effective increase in moving mold length plus a continuity of heat transfer not obtained with prior art belt steering apparatus. (3) The exiting slab is contained and supported downstream from the casting machine to prevent bulging of the shell of the cast product, and (4) spray cooling is incorporated in the exit containment apparatus for secondary cooling of cast product.

  14. Casting evaluation of U-Zr alloy system fuel slug for SFR prepared by injection casting method

    SciTech Connect (OSTI)

    Song, Hoon; Kim, Jong-Hwan; Kim, Ki-Hwan; Lee, Chan-Bock

    2013-07-01

    Metal fuel slugs of U-Pu-Zr alloys for Sodium-cooled Fast Reactor (SFR) have conventionally been fabricated by a vacuum injection casting method. Recently, management of minor actinides (MA) became an important issue because direct disposal of the long-lived MA can be a long-term burden for a tentative repository up to several hundreds of thousand years. In order to recycle transuranic elements (TRU) retained in spent nuclear fuel, remote fabrication capability in a shielded hot cell should be prepared. Moreover, generation of long-lived radioactive wastes and loss of volatile species should be minimized during the recycled fuel fabrication step. In order to prevent the evaporation of volatile elements such as Am, alternative fabrication methods of metal fuel slugs have been studied applying gravity casting, and improved injection casting in KAERI, including melting under inert atmosphere. And then, metal fuel slugs were examined with casting soundness, density, chemical analysis, particle size distribution and microstructural characteristics. Based on these results there is a high level of confidence that Am losses will also be effectively controlled by application of a modest amount of overpressure. A surrogate fuel slug was generally soundly cast by improved injection casting method, melted fuel material under inert atmosphere.

  15. Hickey, C8206_all casts Hickey, C8206_all casts, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, C8206_all casts Hickey, C8206_all casts, page 1 #12;Hickey, C8206_all casts Hickey, C8206_all casts, page 2 #12;Hickey, C8206_all casts Hickey, C8206_all casts, page 3 #12;Hickey, C8206_all casts Hickey, C8206_all casts, page 4 #12;Hickey, C8206_all casts Hickey, C8206_all casts, page 5 #12

  16. FOAM: NOVEL DELIVERY TECHNOLOGY FOR REMEDIATION OF VADOSE ZONE ENVIRONMENTS

    SciTech Connect (OSTI)

    Jansik, Danielle P.; Wellman, Dawn M.; Mattigod, Shas V.; Zhong, Lirong; Wu, Yuxin; Foote, Martin; Zhang, Z. F.; Hubbard, Susan

    2011-07-05

    Deep vadose zone environments can be a primary source and pathway for contaminant migration to groundwater. These environments present unique characterization and remediation challenges that necessitate scrutiny and research. The thickness, depth, and intricacies of the deep vadose zone, combined with a lack of understanding of the key subsurface processes (e.g., biogeochemical and hydrologic) affecting contaminant migration, make it difficult to create validated conceptual and predictive models of subsurface flow dynamics and contaminant behavior across multiple scales. These factors also make it difficult to design and deploy sustainable remedial approaches and monitor long-term contaminant behavior after remedial actions. Functionally, the methods for addressing contamination must remove and/or reduce transport of contaminants. This problem is particularly challenging in the arid western United States where the vadose zone is hundreds of feet thick, rendering transitional excavation methods exceedingly costly and ineffective. Delivery of remedial amendments is one of the most challenging and critical aspects for all remedy-based approaches. The conventional approach for delivery is through injection of aqueous remedial solutions. However, heterogeneous deep vadose zone environments present hydrologic and geochemical challenges which limit the effectiveness. Because the flow of solution infiltration is dominantly controlled by gravity and suction, injected liquid preferentially percolates through highly permeable pathways, by-passing low-permeability zones which frequently contain the majority of contamination. Moreover, the wetting front can readily mobilize and enhance contaminant transport to the underlying aquifer prior to stabilization. Development of innovative, in-situ technologies may be the only way to meet remedial action objectives and long-term stewardship goals. Surfactants can be used to lower the liquid surface tension and create stabile foams, which readily penetrate low permeability zones. Although surfactant foams have been utilized for subsurface mobilization efforts in the oil and gas industry, so far, the concept of using foams as a delivery mechanism for transporting remedial amendments into deep vadose zone environments to stabilize metal and long-lived radionuclide contaminants has not been explored. Foam flow can be directed by pressure gradients, rather than being dominated by gravity; and, foam delivery mechanisms limit the volume of water (< 5% vol.) required for remedy delivery and emplacement, thus mitigating contaminant mobilization. We will present the results of a numerical modeling and integrated laboratory- / intermediate-scale investigation to simulate, develop, demonstrate, and monitor (i.e. advanced geophysical techniques and advanced predictive biomarkers) foam-based delivery of remedial amendments to remediate metals and radionuclides in vadose zone environments.

  17. Effect of Gas Diffusion on Mobility of Foam for Enhanced Oil Recovery Lars E. Nonnekes1

    E-Print Network [OSTI]

    Cox, Simon

    as one reason why CO2 foams for enhanced oil recovery (EOR) are less resistant to flow than N2 foams weakness of CO2 foam therefore evidently lies in factors other than CO2's large diffusion rate through foam. Keywords Foam ·Diffusion · Enhanced oil recovery · Foam stability ·CO2 foam · Steam foam 1 Introduction

  18. Activated, coal-based carbon foam

    DOE Patents [OSTI]

    Rogers, Darren Kenneth; Plucinski, Janusz Wladyslaw

    2004-12-21

    An ablation resistant, monolithic, activated, carbon foam produced by the activation of a coal-based carbon foam through the action of carbon dioxide, ozone or some similar oxidative agent that pits and/or partially oxidizes the carbon foam skeleton, thereby significantly increasing its overall surface area and concurrently increasing its filtering ability. Such activated carbon foams are suitable for application in virtually all areas where particulate or gel form activated carbon materials have been used. Such an activated carbon foam can be fabricated, i.e. sawed, machined and otherwise shaped to fit virtually any required filtering location by simple insertion and without the need for handling the "dirty" and friable particulate activated carbon foam materials of the prior art.

  19. Switching Reversibly between Ultrastable and Unstable Foams

    E-Print Network [OSTI]

    Anne-Laure Fameau; Arnaud Saint-Jalmes; Fabrice Cousin; Bérénice Houinsou Houssou; François Boué; Bruno Novales; Laurence Navailles; Frédéric Nallet; Cédric Gaillard; Jean-Paul Douliez.

    2012-10-21

    Ultrastable foams with an optimal foamability have been obtained using hydroxyl fatty acids tubes. The stabilization results from the adsorption of monomers at the air-water interface preventing coalescence and coarsening and from the presence of tubes in the Plateau borders limiting the drainage. Upon heating, tubes transit to micelles, which induces foam destabilization. Such foams are thus the first to have a temperature tunable stability.

  20. Pitch-based carbon foam and composites

    DOE Patents [OSTI]

    Klett, James W. (Knoxville, TN)

    2002-01-01

    A process for producing carbon foam or a composite is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.

  1. How Bubbly Mixtures Foam and Foam Control Using a Fluidized Bed

    E-Print Network [OSTI]

    Joseph, Daniel D.

    How Bubbly Mixtures Foam and Foam Control Using a Fluidized Bed by Jos e Guiti anz Daniel Joseph to the top because it has a higher gas fraction than the bubbly mixture from which it comes. The high gas slit bubble reactor which when used with aqueous anionic surfactants gives rise to foam. This reactor

  2. Process for preparing silicon carbide foam

    SciTech Connect (OSTI)

    Whinnery, L.L.; Nichols, M.C.; Wheeler, D.R.; Loy, D.A.

    1997-09-16

    A method of preparing near net shape, monolithic, porous SiC foams is disclosed. Organosilicon precursors are used to produce polymeric gels by thermally induced phase separation, wherein, a sufficiently concentrated solution of an organosilicon polymer is cooled below its solidification temperature to form a gel. Following solvent removal from the gel, the polymer foam is pretreated in an oxygen plasma in order to raise its glass transition temperature. The pretreated foam is then pyrolyzed in an inert atmosphere to form a SiC foam. 9 figs.

  3. Process for preparing silicon carbide foam

    SciTech Connect (OSTI)

    Whinnery, LeRoy Louis (Livermore, CA); Nichols, Monte Carl (Livermore, CA); Wheeler, David Roger (Albuquerque, NM); Loy, Douglas Anson (Albuquerque, NM)

    1997-01-01

    A method of preparing near net shape, monolithic, porous SiC foams is disclosed. Organosilicon precursors are used to produce polymeric gels by thermally induced phase separation, wherein, a sufficiently concentrated solution of an organosilicon polymer is cooled below its solidification temperature to form a gel. Following solvent removal from the gel, the polymer foam is pretreated in an oxygen plasma in order to raise its glass transition temperature. The pretreated foam is then pyrolized in an inert atmosphere to form a SiC foam.

  4. Development Program for Natural Aging Aluminum Casting Alloys

    SciTech Connect (OSTI)

    Dr. Geoffrey K. Sigworth

    2004-05-14

    A number of 7xx aluminum casting alloys are based on the ternary Al-Zn-Mg system. These alloys age naturally to high strength at room temperature. A high temperature solution and aging treatment is not required. Consequently, these alloys have the potential to deliver properties nearly equivalent to conventional A356-T6 (Al-Si-Mg) castings, with a significant cost saving. An energy savings is also possible. In spite of these advantages, the 7xx casting alloys are seldom used, primarily because of their reputation for poor castibility. This paper describes the results obtained in a DOE-funded research study of these alloys, which is part of the DOE-OIT ''Cast Metals Industries of the Future'' Program. Suggestions for possible commercial use are also given.

  5. Hickey, TT136, casts 3-5 Hickey, TT136, casts 3-5, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 3-5 Hickey, TT136, casts 3-5, page 1 CTD003 #12;Hickey, TT136, casts 3-5 Hickey, TT136, casts 3-5, page 2 CTD003 #12;Hickey, TT136, casts 3-5 Hickey, TT136, casts 3-5, page 3 CTD003 #12;Hickey, TT136, casts 3-5 Hickey, TT136, casts 3-5, page 4 CTD003 #12;Hickey, TT136, casts 3

  6. Hickey, TT162, Casts 2-5 Hickey, TT162, Casts 2-5, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 2-5 Hickey, TT162, Casts 2-5, page 1 CTD002 #12;Hickey, TT162, Casts 2-5 Hickey, TT162, Casts 2-5, page 2 CTD002 #12;Hickey, TT162, Casts 2-5 Hickey, TT162, Casts 2-5, page 3 CTD002 #12;Hickey, TT162, Casts 2-5 Hickey, TT162, Casts 2-5, page 4 CTD002 #12;Hickey, TT162, Casts 2

  7. Hickey, TT136, casts 6-10 Hickey, TT136, casts 6-10, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 6-10 Hickey, TT136, casts 6-10, page 1 CTD006 #12;Hickey, TT136, casts 6-10 Hickey, TT136, casts 6-10, page 2 CTD006 #12;Hickey, TT136, casts 6-10 Hickey, TT136, casts 6-10, page 3 CTD006 #12;Hickey, TT136, casts 6-10 Hickey, TT136, casts 6-10, page 4 CTD006 #12;Hickey, TT136, casts

  8. Hickey, TT162, casts 6-7 Hickey, TT162, casts 6-7, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    CTD006 Hickey, TT162, casts 6-7 Hickey, TT162, casts 6-7, page 1 #12;CTD006 Hickey, TT162, casts 6-7 Hickey, TT162, casts 6-7, page 2 #12;CTD006 Hickey, TT162, casts 6-7 Hickey, TT162, casts 6-7, page 3 #12;CTD006 Hickey, TT162, casts 6-7 Hickey, TT162, casts 6-7, page 4 #12;CTD006 Hickey, TT162, casts 6

  9. Efficient continuous dryer for flexible polyurethane foam and cleaning apparatus

    DOE Patents [OSTI]

    Jody, B.; Daniels, E.; Libera, J.A.

    1999-03-16

    A method of cleaning polyurethane foams where the material is transported through a wash station while alternately soaking the polyurethane foam in an organic solvent and squeezing solvent from the polyurethane foam a number of times. Then the polyurethane foam is sent through a rinse or solvent transfer station for reducing the concentration of solvent in the foam. The rinsed polyurethane foam is sent to a drying station wherein the foam is repeatedly squeezed while being exposed to hot air to remove wet air from the foam. 4 figs.

  10. Efficient continuous dryer for flexible polyurethane foam and cleaning apparatus

    DOE Patents [OSTI]

    Jody, Bassam (Chicago, IL); Daniels, Edward (Oak Lawn, IL); Libera, Joseph A. (Clarendon Hills, IL)

    1999-01-01

    A method of cleaning polyurethane foams where the material is transported through a wash station while alternately soaking the polyurethane foam in an organic solvent and squeezing solvent from the polyurethane foam a number of times. Then the polyurethane foam is sent through a rinse or solvent transfer station for reducing the concentration of solvent in the foam. The rinsed polyurethane foam is sent to a drying station wherein the foam is repeatedly squeezed while being exposed to hot air to remove wet air from the foam.

  11. Carbon Foam Thermal Management Materials for Electronic Packaging...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Foam Thermal Management Materials for Electronic Packaging Carbon Foam Thermal Management Materials for Electronic Packaging Presentation from the U.S. DOE Office of Vehicle...

  12. A New Generation of Building Insulation by Foaming Polymer Blend...

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    project are: Developing advanced material composites with pore morphology control and CO2 foaming to achieve R-6 per inch foam building insulation at competitive costs;...

  13. Characterization of fold defects in AZ91D and AE42 magnesium alloy permanent mold castings

    SciTech Connect (OSTI)

    Bichler, L. [Centre for Near-net-shape Processing of Materials, Ryerson University, 101 Gerrard St. E., Toronto, M5B 2K3 (Canada); Ravindran, C., E-mail: rravindr@ryerson.ca [Centre for Near-net-shape Processing of Materials, Ryerson University, 101 Gerrard St. E., Toronto, M5B 2K3 (Canada)

    2010-03-15

    Casting premium-quality magnesium alloy components for aerospace and automotive applications poses unique challenges. Magnesium alloys are known to freeze rapidly prior to filling a casting cavity, resulting in misruns and cold shuts. In addition, melt oxidation, solute segregation and turbulent metal flow during casting contribute to the formation of fold defects. In this research, formation of fold defects in AZ91D and AE42 magnesium alloys cast via the permanent mold casting process was investigated. Computer simulations of the casting process predicted the development of a turbulent metal flow in a critical casting region with abrupt geometrical transitions. SEM and light optical microscopy examinations revealed the presence of folds in this region for both alloys. However, each alloy exhibited a unique mechanism responsible for fold formation. In the AZ91D alloy, melt oxidation and velocity gradients in the critical casting region prevented fusion of merging metal front streams. In the AE42 alloy, limited solubility of rare-earth intermetallic compounds in the {alpha}-Mg phase resulted in segregation of Al{sub 2}RE particles at the leading edge of a metal front and created microstructural inhomogeneity across the fold.

  14. MECHANISTIC STUDIES OF IMPROVED FOAM EOR PROCESSES

    SciTech Connect (OSTI)

    William R. Rossen

    2003-03-31

    The objective of this research is to widen the application of foam to enhanced oil recovery (EOR) by investigating fundamental mechanisms of foams in porous media. This research will lay the groundwork for more applied research on foams for improved sweep efficiency in miscible gas, steam and surfactant-based EOR. Task 1 investigates the pore-scale interactions between foam bubbles and polymer molecules. Task 2 examines the mechanisms of gas trapping, and interaction between gas trapping and foam effectiveness. Task 3 investigates mechanisms of foam generation in porous media. The most significant progress during this period was made on Tasks 1 and 3. Research on Task 1 focused on selecting and characterizing a surfactant/polymer formulation for initial experiments. The two (high-quality and low-quality) strong-foam regimes were identified from steady-state coreflood data for the formulation without polymer, for comparison with behavior with polymer. This formulation showed unconventional behavior in the low-quality regime in that pressure gradient decreases at increasing liquid injection rate. Such behavior was not seen in most previous studies of foam, but it is consistent with dense-CO{sub 2} foam data recently obtained in our laboratory. We are considering the significance of the unconventional trend in the data and proceeding with initial experiments with polymer. Research on Task 3 focused on foam generation at limited pressure gradient in sandpacks. In these experiments liquid injection rate and pressure drop across the core are held fixed, and gas injection rate responds to creation and properties of foam. Initial experiments included three permeabilities (1.2, 3.6 and 5 darcy), three surfactant concentrations (0.12, 1.2 and 2.4 wt%) and two liquid injection rates (1.29 and 2.76 ft/day). Separating experimental artifacts from physical phenomena in these experiments is difficult and an ongoing process.

  15. Extrusion cast explosive

    DOE Patents [OSTI]

    Scribner, K.J.

    1985-11-26

    Disclosed is an improved, multiphase, high performance, high energy, extrusion cast explosive compositions, comprising, a crystalline explosive material; an energetic liquid plasticizer; a urethane prepolymer, comprising a blend of polyvinyl formal, and polycaprolactone; a polyfunctional isocyanate; and a catalyst. These new explosive compositions exhibit higher explosive content, a smooth detonation front, excellent stability over long periods of storage, and lower sensitivity to mechanical stimulants. 1 fig.

  16. Extrusion cast explosive

    DOE Patents [OSTI]

    Scribner, K.J.

    1985-01-29

    Improved, multiphase, high performance, high energy, extrusion cast explosive compositions, comprising, a crystalline explosive material; an energetic liquid plasticizer; a urethane prepolymer, comprising a blend of polyvinyl formal, and polycaprolactone; a polyfunctional isocyanate; and a catalyst are disclosed. These new explosive compositions exhibit higher explosive content, a smooth detonation front, excellent stability over long periods of storage, and lower sensitivity to mechanical stimulants. 1 fig.

  17. The Crystallization Behavior of Porous PLA Prepared by Modified Solvent Casting/Particulate Leaching Technique for Potential Use of Tissue Engineering Scaffold

    E-Print Network [OSTI]

    Ran Huang; Xiaomin Zhu; Haiyan Tu; Ajun Wan

    2014-04-14

    The porous PLA foams potential for tissue engineering usage are prepared by a modified solvent casting/particulate leaching method with different crystallinity. Since in typical method the porogens are solved in the solution and flow with the polymers during the casting and the crystallinity behavior of PLA chains in the limited space cannot be tracked, in this work the processing is modified by diffusing the PLA solution into a steady salt stack. With a thermal treatment before leaching while maintaining the stable structure of the porogens stack, the crystallinity of porous foams is made possible to control. The characterizations indicate the crystallization of porous foams is in a manner of lower crystallibility than the bulk materials. Pores and caves of around 250{\\mu}m size are obtained in samples with different crystallinity. The macro-structures are not much impaired by the crystallization nevertheless the morphological effect of the heating process is still obvious.

  18. Couette Flow of Two-Dimensional Foams

    E-Print Network [OSTI]

    G. Katgert; B. P. Tighe; M. E. Möbius; M. van Hecke

    2010-04-26

    We experimentally investigate flow of quasi two-dimensional disordered foams in Couette geometries, both for foams squeezed below a top plate and for freely floating foams. With the top-plate, the flows are strongly localized and rate dependent. For the freely floating foams the flow profiles become essentially rate-independent, the local and global rheology do not match, and in particular the foam flows in regions where the stress is below the global yield stress. We attribute this to nonlocal effects and show that the "fluidity" model recently introduced by Goyon {\\em et al.} ({\\em Nature}, {\\bf 454} (2008)) captures the essential features of flow both with and without a top plate.

  19. Foam generator and viscometer apparatus and process

    DOE Patents [OSTI]

    Reed, Troy D.; Pickell, Mark B.; Volk, Leonard J.

    2004-10-26

    An apparatus and process to generate a liquid-gas-surfactant foam and to measure its viscosity and enable optical and or electronic measurements of physical properties. The process includes the steps of pumping selected and measured liquids and measured gases into a mixing cell. The mixing cell is pressurized to a desired pressure and maintained at a desired pressure. Liquids and gas are mixed in the mixing cell to produce a foam of desired consistency. The temperature of the foam in the mixing cell is controlled. Foam is delivered from the mixing cell through a viscometer under controlled pressure and temperature conditions where the viscous and physical properties of the foam are measured and observed.

  20. Prediction of Reoxidation Inclusion Composition in Casting of Steel

    E-Print Network [OSTI]

    Beckermann, Christoph

    in the production of steel castings. Removing inclusions and refilling the defect areas with the weld metal account in steel with oxygen during pouring of the (deoxidized) steel from the ladle into the mold. Oxy- gen may come from the surrounding atmosphere, refracto- ries, slag, or the sand mold.[3] The atmosphere

  1. Simulation of Reoxidation Inclusion Formation in Steel Casting

    E-Print Network [OSTI]

    Beckermann, Christoph

    the risers, and the ability of inclusions to adhere to mold walls. Recommendations for future research castings is due to the removal of inclusions and the repair of the resulting defect areas with weld metal comes into contact with oxygen during mold filling, make up a substantial portion of the inclusions

  2. Foams Stabilized by Tricationic Amphiphilic Surfactants

    E-Print Network [OSTI]

    Seth Heerschap; John N. Marafino; Kristin McKenna; Kevin L. Caran; Klebert Feitosa

    2015-09-11

    The unique surface properties of amphiphilic molecules have made them widely used in applications where foaming, emulsifying or coating processes are needed. Novel surfactant architectures with multi-cephalic and multi-tailed molecules have reportedly enhanced their anti-bacterial activity in connection with tail length and the nature of the head group, but their ability to produce and stabilize foam is mostly unknown. Here we report on experiments with tris-cationic, triple-headed, double- and single-tailed amphiphiles and their foamability and foam stability with respect to head group, tail number and tail length. The amphiphiles are composed of an aromatic mesitylene core and three benzylic amonium bromide groups, with alkyl chains attached to one or two of the head groups. Whereas shorter (14 carbons in length) double-tailed molecules are found to produce very stable foams, foams made with single tail molecules of the same length show poor foamability and stability, and foams with longer (16 carbons in length) double-tail molecules do not foam with the methods used. By contrast, the structure of the non-tail-bearing head group (trimethylammonium vs. pyridinium) has no impact on foamability. Furthermore, observations of the coarsening rate at nearly constant liquid content indicate that the enhanced foam stability is a result of lower gas permeability through the surfactant monolayer. Finally, the critical aggregation concentration (CAC) of the surfactants demonstrates to be a good predictor of foamability and foam stability for these small molecule surfactants. This results inform how surfactant architecture can be tailored to produce stable foams.

  3. Cast dielectric composite linear accelerator

    DOE Patents [OSTI]

    Sanders, David M. (Livermore, CA); Sampayan, Stephen (Manteca, CA); Slenes, Kirk (Albuquerque, NM); Stoller, H. M. (Albuquerque, NM)

    2009-11-10

    A linear accelerator having cast dielectric composite layers integrally formed with conductor electrodes in a solventless fabrication process, with the cast dielectric composite preferably having a nanoparticle filler in an organic polymer such as a thermosetting resin. By incorporating this cast dielectric composite the dielectric constant of critical insulating layers of the transmission lines of the accelerator are increased while simultaneously maintaining high dielectric strengths for the accelerator.

  4. Hickey, TT136, casts 56-76 Hickey, TT136, casts 56-76, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 56-76 Hickey, TT136, casts 56-76, page 1 CTD056 #12;Hickey, TT136, casts 56-76 Hickey, TT136, casts 56-76, page 2 CTD056 #12;Hickey, TT136, casts 56-76 Hickey, TT136, casts 56-76, page 3 CTD056 #12;Hickey, TT136, casts 56-76 Hickey, TT136, casts 56-76, page 4 CTD056 #12;Hickey, TT136

  5. Hickey, TT162, Casts 38-47 Hickey, TT162, Casts 38-47, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 38-47 Hickey, TT162, Casts 38-47, page 1 CTD038 #12;Hickey, TT162, Casts 38-47 Hickey, TT162, Casts 38-47, page 2 CTD039 #12;Hickey, TT162, Casts 38-47 Hickey, TT162, Casts 38-47, page 3 CTD039 #12;Hickey, TT162, Casts 38-47 Hickey, TT162, Casts 38-47, page 4 CTD040 #12;Hickey, TT162

  6. Hickey, TT162, Casts 63-72 Hickey, TT162, Casts 63-72, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 63-72 Hickey, TT162, Casts 63-72, page 1 CTD063 #12;Hickey, TT162, Casts 63-72 Hickey, TT162, Casts 63-72, page 2 CTD063 #12;Hickey, TT162, Casts 63-72 Hickey, TT162, Casts 63-72, page 3 CTD063 #12;Hickey, TT162, Casts 63-72 Hickey, TT162, Casts 63-72, page 4 CTD064 #12;Hickey, TT162

  7. Hickey, TT162, Casts 48-49 Hickey, TT162, Casts 48-49, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 48-49 Hickey, TT162, Casts 48-49, page 1 CTD048 #12;Hickey, TT162, Casts 48-49 Hickey, TT162, Casts 48-49, page 2 CTD048 #12;Hickey, TT162, Casts 48-49 Hickey, TT162, Casts 48-49, page 3 CTD048 #12;Hickey, TT162, Casts 48-49 Hickey, TT162, Casts 48-49, page 4 CTD048 #12;Hickey, TT162

  8. Hickey, TT136, casts 98-99 Hickey, TT136, casts 98-99, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 98-99 Hickey, TT136, casts 98-99, page 1 CTD098 #12;Hickey, TT136, casts 98-99 Hickey, TT136, casts 98-99, page 2 CTD098 #12;Hickey, TT136, casts 98-99 Hickey, TT136, casts 98-99, page 3 CTD098 #12;Hickey, TT136, casts 98-99 Hickey, TT136, casts 98-99, page 4 CTD098 #12;Hickey, TT136

  9. Hickey, TT162, Casts 73-82 Hickey, TT162, Casts 73-82, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 73-82 Hickey, TT162, Casts 73-82, page 1 CTD073 #12;Hickey, TT162, Casts 73-82 Hickey, TT162, Casts 73-82, page 2 CTD073 #12;Hickey, TT162, Casts 73-82 Hickey, TT162, Casts 73-82, page 3 CTD073 #12;Hickey, TT162, Casts 73-82 Hickey, TT162, Casts 73-82, page 4 CTD074 #12;Hickey, TT162

  10. Hickey, TT136, casts 48, 49, 51 Hickey, TT136, casts 48, 49, 51, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 48, 49, 51 Hickey, TT136, casts 48, 49, 51, page 1 CTD048 #12;Hickey, TT136, casts 48, 49, 51 Hickey, TT136, casts 48, 49, 51, page 2 CTD048 #12;Hickey, TT136, casts 48, 49, 51 Hickey, TT136, casts 48, 49, 51, page 3 CTD048 #12;Hickey, TT136, casts 48, 49, 51 Hickey, TT136, casts

  11. Hickey, TT136, casts 41-43 Hickey, TT136, casts 41-43, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    CTD041 Hickey, TT136, casts 41-43 Hickey, TT136, casts 41-43, page 1 #12;CTD041 Hickey, TT136, casts 41-43 Hickey, TT136, casts 41-43, page 2 #12;CTD041 Hickey, TT136, casts 41-43 Hickey, TT136, casts 41-43, page 3 #12;CTD041 Hickey, TT136, casts 41-43 Hickey, TT136, casts 41-43, page 4 #12;CTD041

  12. Hickey, TT136, casts 27-36 Hickey, TT136, casts 27-36, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 27-36 Hickey, TT136, casts 27-36, page 1 CTD027 #12;Hickey, TT136, casts 27-36 Hickey, TT136, casts 27-36, page 2 CTD027 #12;Hickey, TT136, casts 27-36 Hickey, TT136, casts 27-36, page 3 CTD027 #12;Hickey, TT136, casts 27-36 Hickey, TT136, casts 27-36, page 4 CTD027 #12;Hickey, TT136

  13. Hickey, TT162, Casts 88-92 Hickey, TT162, Casts 88-92, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 88-92 Hickey, TT162, Casts 88-92, page 1 CTD088 #12;Hickey, TT162, Casts 88-92 Hickey, TT162, Casts 88-92, page 2 CTD088 #12;Hickey, TT162, Casts 88-92 Hickey, TT162, Casts 88-92, page 3 CTD088 #12;Hickey, TT162, Casts 88-92 Hickey, TT162, Casts 88-92, page 4 CTD088 #12;Hickey, TT162

  14. Hickey, TT136, casts 44-46 Hickey, TT136, casts 44-46, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 44-46 Hickey, TT136, casts 44-46, page 1 CTD044 #12;Hickey, TT136, casts 44-46 Hickey, TT136, casts 44-46, page 2 CTD044 #12;Hickey, TT136, casts 44-46 Hickey, TT136, casts 44-46, page 3 CTD044 #12;Hickey, TT136, casts 44-46 Hickey, TT136, casts 44-46, page 4 CTD044 #12;Hickey, TT136

  15. Hickey, W8201, casts 26-32 Hickey, W8201, casts 26-32, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8201, casts 26-32 Hickey, W8201, casts 26-32, page 1 CTD026 #12;Hickey, W8201, casts 26-32 Hickey, W8201, casts 26-32, page 2 CTD026 #12;Hickey, W8201, casts 26-32 Hickey, W8201, casts 26-32, page 3 CTD027 #12;Hickey, W8201, casts 26-32 Hickey, W8201, casts 26-32, page 4 CTD027 #12;Hickey, W8201

  16. Hickey, TT162, Casts 17-24 Hickey, TT162, Casts 17-24, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 17-24 Hickey, TT162, Casts 17-24, page 1 CTD017 #12;Hickey, TT162, Casts 17-24 Hickey, TT162, Casts 17-24, page 2 CTD017 #12;Hickey, TT162, Casts 17-24 Hickey, TT162, Casts 17-24, page 3 CTD018 #12;Hickey, TT162, Casts 17-24 Hickey, TT162, Casts 17-24, page 4 CTD018 #12;Hickey, TT162

  17. Hickey, TT162, Casts 83-87 Hickey, TT162, Casts 83-87, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 83-87 Hickey, TT162, Casts 83-87, page 1 CTD083 #12;Hickey, TT162, Casts 83-87 Hickey, TT162, Casts 83-87, page 2 CTD083 #12;Hickey, TT162, Casts 83-87 Hickey, TT162, Casts 83-87, page 3 CTD083 #12;Hickey, TT162, Casts 83-87 Hickey, TT162, Casts 83-87, page 4 CTD083 #12;Hickey, TT162

  18. Hickey, TT136, casts 77-90 Hickey, TT136, casts 77-90, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 77-90 Hickey, TT136, casts 77-90, page 1 CTD077 #12;Hickey, TT136, casts 77-90 Hickey, TT136, casts 77-90, page 2 CTD077 #12;Hickey, TT136, casts 77-90 Hickey, TT136, casts 77-90, page 3 CTD077 #12;Hickey, TT136, casts 77-90 Hickey, TT136, casts 77-90, page 4 CTD077 #12;Hickey, TT136

  19. Hickey, TT162, Casts 56-62 Hickey, TT162, Casts 56-62, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT162, Casts 56-62 Hickey, TT162, Casts 56-62, page 1 CTD056 #12;Hickey, TT162, Casts 56-62 Hickey, TT162, Casts 56-62, page 2 CTD056 #12;Hickey, TT162, Casts 56-62 Hickey, TT162, Casts 56-62, page 3 CTD056 #12;Hickey, TT162, Casts 56-62 Hickey, TT162, Casts 56-62, page 4 CTD056 #12;Hickey, TT162

  20. Hickey, TT136, casts 96-97 Hickey, TT136, casts 96-97, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 96-97 Hickey, TT136, casts 96-97, page 1 CTD096 #12;Hickey, TT136, casts 96-97 Hickey, TT136, casts 96-97, page 2 CTD096 #12;Hickey, TT136, casts 96-97 Hickey, TT136, casts 96-97, page 3 CTD096 #12;Hickey, TT136, casts 96-97 Hickey, TT136, casts 96-97, page 4 CTD096 #12;Hickey, TT136

  1. Hickey, TT136, casts 21-26 Hickey, TT136, casts 21-26, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 21-26 Hickey, TT136, casts 21-26, page 1 CTD021 #12;Hickey, TT136, casts 21-26 Hickey, TT136, casts 21-26, page 2 CTD021 #12;Hickey, TT136, casts 21-26 Hickey, TT136, casts 21-26, page 3 CTD021 #12;Hickey, TT136, casts 21-26 Hickey, TT136, casts 21-26, page 4 CTD021 #12;Hickey, TT136

  2. Hickey, TT136, casts 37-40 Hickey, TT136, casts 37-40, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    CTD037 Hickey, TT136, casts 37-40 Hickey, TT136, casts 37-40, page 1 #12;CTD037 Hickey, TT136, casts 37-40 Hickey, TT136, casts 37-40, page 2 #12;CTD037 Hickey, TT136, casts 37-40 Hickey, TT136, casts 37-40, page 3 #12;CTD037 Hickey, TT136, casts 37-40 Hickey, TT136, casts 37-40, page 4 #12;CTD037

  3. Hickey, W8201, casts 11-18 Hickey, W8201, casts 11-18, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8201, casts 11-18 Hickey, W8201, casts 11-18, page 1 CTD011 #12;Hickey, W8201, casts 11-18 Hickey, W8201, casts 11-18, page 2 CTD011 #12;Hickey, W8201, casts 11-18 Hickey, W8201, casts 11-18, page 3 CTD011 #12;Hickey, W8201, casts 11-18 Hickey, W8201, casts 11-18, page 4 CTD011 #12;Hickey, W8201

  4. Hickey, TT136, casts 46-47 Hickey, TT136, casts 46-47, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 46-47 Hickey, TT136, casts 46-47, page 1 CTD046 #12;Hickey, TT136, casts 46-47 Hickey, TT136, casts 46-47, page 2 CTD046 #12;Hickey, TT136, casts 46-47 Hickey, TT136, casts 46-47, page 3 CTD046 #12;Hickey, TT136, casts 46-47 Hickey, TT136, casts 46-47, page 4 CTD046 #12;Hickey, TT136

  5. Hickey, TT136, casts 52-55 Hickey, TT136, casts 52-55, pager 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 52-55 Hickey, TT136, casts 52-55, pager 1 CTD052 #12;Hickey, TT136, casts 52-55 Hickey, TT136, casts 52-55, pager 2 CTD052 #12;Hickey, TT136, casts 52-55 Hickey, TT136, casts 52-55, pager 3 CTD052 #12;Hickey, TT136, casts 52-55 Hickey, TT136, casts 52-55, pager 4 CTD052 #12;Hickey, TT

  6. Hickey, TT136, casts 91-95 Hickey, TT136, casts 91-95, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 91-95 Hickey, TT136, casts 91-95, page 1 CTD091 #12;Hickey, TT136, casts 91-95 Hickey, TT136, casts 91-95, page 2 CTD091 #12;Hickey, TT136, casts 91-95 Hickey, TT136, casts 91-95, page 3 CTD091 #12;Hickey, TT136, casts 91-95 Hickey, TT136, casts 91-95, page 4 CTD091 #12;Hickey, TT136

  7. Hickey, W8201, Casts 1-10 Hickey, W8201, Casts 1-10, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    CTD001 Hickey, W8201, Casts 1-10 Hickey, W8201, Casts 1-10, page 1 #12;CTD001 Hickey, W8201, Casts 1-10 Hickey, W8201, Casts 1-10, page 2 #12;CTD002 Hickey, W8201, Casts 1-10 Hickey, W8201, Casts 1-10, page 3 #12;CTD002 Hickey, W8201, Casts 1-10 Hickey, W8201, Casts 1-10, page 4 #12;CTD003 Hickey, W8201

  8. Hickey, TT136, casts 11-20 Hickey, TT136, casts 11-20, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, TT136, casts 11-20 Hickey, TT136, casts 11-20, page 1 CTD011 #12;Hickey, TT136, casts 11-20 Hickey, TT136, casts 11-20, page 2 CTD011 #12;Hickey, TT136, casts 11-20 Hickey, TT136, casts 11-20, page 3 CTD012 #12;Hickey, TT136, casts 11-20 Hickey, TT136, casts 11-20, page 4 CTD013 #12;Hickey, TT136

  9. Die Casting Copper Motor Rotors

    Broader source: Energy.gov [DOE]

    Though it conducts electricity less efficiently than copper, aluminum is the industry’s preferred fabrication material in electric induction motor rotors. Traditional tool steel casting molds...

  10. Understanding the Relationship Between Filling Pattern and Part Quality in Die Casting

    SciTech Connect (OSTI)

    Jerald Brevick; R. Allen Miller

    2004-03-15

    The overall objective of this research project was to investigate phenomena involved in the filling of die cavities with molten alloy in the cold chamber die-casting process. It has long been recognized that the filling pattern of molten metal entering a die cavity influences the quality of die-cast parts. Filling pattern may be described as the progression of molten metal filling the die cavity geometry as a function of time. The location, size and geometric configuration of points of metal entry (gates), as well as the geometry of the casting cavity itself, have great influence on filling patterns. Knowledge of the anticipated filling patterns in die-castings is important for designers. Locating gates to avoid undesirable flow patterns that may entrap air in the casting is critical to casting quality - as locating vents to allow air to escape from the cavity (last places to fill). Casting quality attributes that are commonly flow related are non-fills, poor surface finish, internal porosity due to trapped air, cold shuts, cold laps, flow lines, casting skin delamination (flaking), and blistering during thermal treatment.

  11. Seal welded cast iron nuclear waste container

    DOE Patents [OSTI]

    Filippi, Arthur M. (Pittsburgh, PA); Sprecace, Richard P. (Murrysville, PA)

    1987-01-01

    This invention identifies methods and articles designed to circumvent metallurgical problems associated with hermetically closing an all cast iron nuclear waste package by welding. It involves welding nickel-carbon alloy inserts which are bonded to the mating plug and main body components of the package. The welding inserts might be bonded in place during casting of the package components. When the waste package closure weld is made, the most severe thermal effects of the process are restricted to the nickel-carbon insert material which is far better able to accommodate them than is cast iron. Use of nickel-carbon weld inserts should eliminate any need for pre-weld and post-weld heat treatments which are a problem to apply to nuclear waste packages. Although the waste package closure weld approach described results in a dissimilar metal combination, the relative surface area of nickel-to-iron, their electrochemical relationship, and the presence of graphite in both materials will act to prevent any galvanic corrosion problem.

  12. Volume equalized constitutive equations for foamed polymer solutions

    E-Print Network [OSTI]

    Valkó, Peter

    Volume equalized constitutive equations for foamed polymer solutions P. Valko and M. J. Economides; accepted 21 April 1992) Synopsis In order to develop a constitutive equation for foamed polymer solutions Hydroxypropylguar (HPG) solutions containing a small amount of foaming agent and foamed by nitrogen and/or carbon

  13. High temperature adhesive silicone foam composition, foam generating system and method of generating foam. [For access denial

    DOE Patents [OSTI]

    Mead, J.W.; Montoya, O.J.; Rand, P.B.; Willan, V.O.

    1983-12-21

    Access to a space is impeded by generation of a sticky foam from a silicone polymer and a low boiling solvent such as a halogenated hydrocarbon. In a preferred aspect, the formulation is polydimethylsiloxane gel mixed with F502 Freon as a solvent and blowing agent, and pressurized with CO/sub 2/ in a vessel to about 250 PSI, whereby when the vessel is opened, a sticky and solvent resistant foam is deployed. The foam is deployable, over a wide range of temperatures, adhering to wet surfaces as well as dry, is stable over long periods of time and does not propagate flame or lose adhesive properties during an externally supported burn.

  14. Compounding and foaming of microfibrillatedCompounding and foaming of microfibrillated cellulose and polylactic acid biocompositescellulose and polylactic acid biocomposites

    E-Print Network [OSTI]

    Psaltis, Demetri

    foamed with supercritical carbon dioxide (CO2) under different conditions. The structure of the foams CO2 foaming, based on the instability of fluids above the critical temperature and critical pressure foams. CO2 blowing agent was chosen due to its chemical environmental (non-toxic) and economic

  15. The physical properties of microcellular composite foams

    SciTech Connect (OSTI)

    Nyitray, A.M.; Williams, J.M.; Onn, D.; Witek, A. (Los Alamos National Lab., NM (USA); Delaware Univ., Newark, DE (USA). Applied Thermal Physics Lab.)

    1989-01-01

    Recently we reported on a method of preparing microcellular composite foams. In this procedure an open-celled polystyrene foam is prepared by the polymerization of a high-internal-phase water-in-oil emulsion containing styrene, divinylbenzene, surfactant, free-radial initiator and water. After drying, the cells of the polystyrene foam are then filled with other materials such as aerogel or resoles. The physical properties of these materials, e.g., surface area, density, thermal conductivity, and compressive strength will be presented. 10 refs., 1 fig., 3 tabs.

  16. Carbon foams for energy storage devices

    DOE Patents [OSTI]

    Kaschmitter, James L. (Pleasanton, CA); Mayer, Steven T. (San Leandro, CA); Pekala, Richard W. (Pleasant Hill, CA)

    1996-01-01

    A high energy density capacitor incorporating a variety of carbon foam electrodes is described. The foams, derived from the pyrolysis of resorcinol-formaldehyde and related polymers, are high density (0.1 g/cc-1.0 g/cc) electrically conductive and have high surface areas (400 m.sup.2 /g-1000 m.sup.2 /g). Capacitances on the order of several tens of farad per gram of electrode are achieved.

  17. Statistical Mechanics of Two-dimensional Foams

    E-Print Network [OSTI]

    Marc Durand

    2010-09-07

    The methods of statistical mechanics are applied to two-dimensional foams under macroscopic agitation. A new variable -- the total cell curvature -- is introduced, which plays the role of energy in conventional statistical thermodynamics. The probability distribution of the number of sides for a cell of given area is derived. This expression allows to correlate the distribution of sides ("topological disorder") to the distribution of sizes ("geometrical disorder") in a foam. The model predictions agree well with available experimental data.

  18. Carbon foams for energy storage devices

    DOE Patents [OSTI]

    Kaschmitter, J.L.; Mayer, S.T.; Pekala, R.W.

    1996-06-25

    A high energy density capacitor incorporating a variety of carbon foam electrodes is described. The foams, derived from the pyrolysis of resorcinol-formaldehyde and related polymers, are high density (0.1 g/cc--1.0 g/cc) electrically conductive and have high surface areas (400 m{sup 2}/g-1000 m{sup 2}/g). Capacitances on the order of several tens of farad per gram of electrode are achieved. 9 figs.

  19. Hickey -TT174, casts 1 to cast 11 Cruise cast lat (dd.mm.m) lon(dd.mm.m) Date/Time (MMDDYYHHMM) Total Scan

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey -TT174, casts 1 to cast 11 Cruise cast lat (dd.mm.m) lon(dd.mm.m) Date/Time (MMDDYYHHMM;Hickey -TT174, casts 1 to cast 11 Cruise cast lat (dd.mm.m) lon(dd.mm.m) Date/Time (MMDDYYHHMM) Total -TT174, casts 1 to cast 11 Cruise cast lat (dd.mm.m) lon(dd.mm.m) Date/Time (MMDDYYHHMM) Total Scan

  20. Structural Analysis of Sandwich Foam Panels

    SciTech Connect (OSTI)

    Kosny, Jan [ORNL; Huo, X. Sharon [Tennessee Technological University

    2010-04-01

    The Sandwich Panel Technologies including Structural Insulated Panels (SIPs) can be used to replace the conventional wooden-frame construction method. The main purpose of this Cooperative Research and Development Agreement (CRADA) between UT-Battelle, LLC and SGI Venture, Inc. was to design a novel high R-value type of metal sandwich panelized technology. This CRADA project report presents design concept discussion and numerical analysis results from thermal performance study of this new building envelope system. The main objective of this work was to develop a basic concept of a new generation of wall panel technologies which will have R-value over R-20 will use thermal mass to improve energy performance in cooling dominated climates and will be 100% termite resistant. The main advantages of using sandwich panels are as follows: (1) better energy saving structural panels with high and uniform overall wall R-value across the elevation that could not be achieved in traditional walls; and (2) reducing the use of raw materials or need for virgin lumber. For better utilization of these Sandwich panels, engineers need to have a thorough understanding of the actual performance of the panels and system. Detailed analysis and study on the capacities and deformation of individual panels and its assembly have to be performed to achieve that goal. The major project activity was to conduct structural analysis of the stresses, strains, load capacities, and deformations of individual sandwich components under various load cases. The analysis simulated the actual loading conditions of the regular residential building and used actual material properties of the steel facings and foam.

  1. Hickey -TT136 casts 1-2 Hickey -TT136,Casts 1-2, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey -TT136 casts 1-2 Hickey -TT136,Casts 1-2, page 1 CTD001 #12;Hickey -TT136 casts 1-2 Hickey -TT136,Casts 1-2, page 2 CTD001 #12;Hickey -TT136 casts 1-2 Hickey -TT136,Casts 1-2, page 3 CTD001 #12;Hickey -TT136 casts 1-2 Hickey -TT136,Casts 1-2, page 4 CTD001 #12;Hickey -TT136 casts 1-2 Hickey -TT136

  2. Pre-Cast Gel Electrophoresis Guide

    E-Print Network [OSTI]

    Kirschner, Marc W.

    Novex® Pre-Cast Gel Electrophoresis Guide Version B January 27, 2003 IM-1002 Novex® Pre-Cast Gel Electrophoresis Guide General information and protocols for using Novex® pre-cast gels www.invitrogen.com tech.....................................................................................................................1 Novex® Pre-Cast Gels

  3. RELIABILITY-BASED CASTING PROCESS DESIGN OPTIMIZATION

    E-Print Network [OSTI]

    Beckermann, Christoph

    , shrinkage porosity in the casting. Despite the power and promise of these developments in casting processRELIABILITY-BASED CASTING PROCESS DESIGN OPTIMIZATION Richard Hardin1 , K.K. Choi1 , and Christoph 52242-1527 Keywords: Casting Process Design, Optimization, Reliability-Based Design Optimization

  4. Reliability based casting process design optimisation

    E-Print Network [OSTI]

    Beckermann, Christoph

    , which is typically defined as an absence of, or low level of, shrinkage porosity in the casting. DespiteReliability based casting process design optimisation R. A. Hardin, K. K. Choi, N. J. Gaul and C and physical uncertainties in the casting process. In the present research, casting simulation is integrated

  5. Metal Compression Forming of aluminum alloys and metal matrix composites

    SciTech Connect (OSTI)

    Viswanathan, S.; Ren, W.; Porter, W.D.; Brinkman, C.R.; Sabau, A.S.; Purgert, R.M.

    2000-02-01

    Metal Compression Forming (MCF) is a variant of the squeeze casting process, in which molten metal is allowed to solidify under pressure in order to close porosity and form a sound part. However, the MCF process applies pressure on the entire mold face, thereby directing pressure on all regions of the casting and producing a uniformly sound part. The process is capable of producing parts with properties close to those of forgings, while retaining the near net shape, complexity in geometry, and relatively low cost of the casting process.

  6. Rapid prototyping: A paradigm shift in investment casting

    SciTech Connect (OSTI)

    Atwood, C.L.; Maguire, M.C.; Baldwin, M.D.; Pardo, B.T.

    1996-09-01

    The quest for fabricating complex metal parts rapidly and with minimal cost has brought rapid prototyping (RP) processes to the forefront of the investment casting industry. Relatively recent advances in DTM Corporation`s selective laser sintering (SLS) and 3D Systems stereolithography (SL) processes have had a significant impact on the overall quality of patterns produced using these rapid prototyping processes. Sandia National Laboratories uses patterns generated from rapid prototyping processes to reduce the cycle time and cost of fabricating prototype and small lot production parts in support of a program called FASTCAST. The SLS process is used to fabricate patterns from materials such as investment casting wax, polycarbonate, and a new material called TrueForm PM{trademark}. With the timely introduction of each of these materials, the quality of patterns fabricated has improved. The development and implementation of SL QuickCast{trademark} software has enabled this process to produce highly accurate patterns for use in investment casting. This paper focuses on the successes with these new pattern materials and the infrastructure required to cast rapid prototyping patterns successfully. In addition, a brief overview of other applications of rapid prototyping at Sandia will be discussed.

  7. DESIGN AND FABRICATION OF A RECTANGULAR HE-COOLED REFRACTORY FOAM HX-CHANNEL FOR DIVERTOR APPLICATIONS

    E-Print Network [OSTI]

    Ghoniem, Nasr M.

    .williams@ultramet.com A rectangular single channel low pressure drop helium-cooled refractory metal heat exchanger (HX) tube the path of helium flow through foam to about 11 mm and thus the pressure drop through the porous media surfaces, such as a flat-plate divertor, without substantially increasing the coolant pressure losses. We

  8. BIOMIMETIC PROCESSING OF CERAMICS AND CERAMIC-METAL COMPOSITES

    E-Print Network [OSTI]

    Aksay, Ilhan A.

    625 BIOMIMETIC PROCESSING OF CERAMICS AND CERAMIC-METAL COMPOSITES M. YASREBI, G. H. KIM, K. E by a combination of tape casting of the ceramic and infiltration of the metal. The resultant cermets displayed a 40 such as metal-metal,' metal-ceramic,2 internietallic-intermetallic,1 metal-intermetallic,3 and ceramic-ceramic4

  9. ITP Metal Casting: Energy and Environmental Profile of the U.S. Metal casting Industry

    Office of Energy Efficiency and Renewable Energy (EERE)

    The DOE's Office of Industrial Technologies has formed apartnership with the U.S. metalcasting industry to accelerate the development of technoloiges and processes that will improve the industry's energy efficiency and environmental performance.

  10. ITP Metal Casting: A Vision for the U.S. Metal Casting Industry: 2002 and Beyond

    Broader source: Energy.gov [DOE]

    The U.S. metalcasting industry will exhibit increased strength, vitality and innovation, contributing to the nation’s economy and security.

  11. Radiative transfer and thermal performance levels in foam insulation boardstocks

    E-Print Network [OSTI]

    Moreno, John David

    1991-01-01

    The validity of predictive models for the thermal conductivity of foam insulation is established based on the fundamental geometry of the closed-cell foam. The extinction coefficient is experimentally and theoretically ...

  12. Flow transitions in two-dimensional foams

    E-Print Network [OSTI]

    Christopher Gilbreth; Scott Sullivan; Michael Dennin

    2006-08-08

    For sufficiently slow rates of strain, flowing foam can exhibit inhomogeneous flows. The nature of these flows is an area of active study in both two-dimensional model foams and three dimensional foam. Recent work in three-dimensional foam has identified three distinct regimes of flow [S. Rodts, J. C. Baudez, and P. Coussot, Europhys. Lett. {\\bf 69}, 636 (2005)]. Two of these regimes are identified with continuum behavior (full flow and shear-banding), and the third regime is identified as a discrete regime exhibiting extreme localization. In this paper, the discrete regime is studied in more detail using a model two dimensional foam: a bubble raft. We characterize the behavior of the bubble raft subjected to a constant rate of strain as a function of time, system size, and applied rate of strain. We observe localized flow that is consistent with the coexistence of a power-law fluid with rigid body rotation. As a function of applied rate of strain, there is a transition from a continuum description of the flow to discrete flow when the thickness of the flow region is approximately 10 bubbles. This occurs at an applied rotation rate of approximately $0.07 {\\rm s^{-1}}$.

  13. Yielding and flow of foamed metakaolin pastes

    E-Print Network [OSTI]

    Lucie Ducloué; Olivier Pitois; Laurent Tocquer; Julie Goyon; Guillaume Ovarlez

    2015-10-01

    Metakaolin is a broadly used industrial raw material, with applications in the production of ceramics and geopolymers, and the partial replacement of Portland cement. The early stages of the manufacturing of some of these materials require the preparation and processing of a foamed metakaolin-based slurry. In this study, we propose to investigate the rheology of a foamed metakaolin-based fresh paste by performing well-controlled experiments. We work with a non-reactive metakaolin paste containing surfactant, in which we disperse bubbles of known radius at a chosen volume fraction. We perform rheometry measurements to characterize the minimum stress required for the foamed materials to flow (yield stress), and the dissipation occurring during flow. We show that the yield stress of the foamed samples is equal to the one of the metakaolin paste, and that dissipation during flow increases quadratically with the bubble volume fraction. Comparison with yielding and flow of model foamed yield stress fluids allows us to understand these results in terms of coupling between the bubbles' surface tension and the metakaolin paste's rheology.

  14. Method for making one-container rigid foam

    DOE Patents [OSTI]

    Aubert, James H.

    2005-04-12

    A method of making a one-container foam by dissolving a polymer in liquified gas at a pressure greater than the vapor pressure of the liquified gas and than rapidly decreasing the pressure within approximately 60 seconds to foam a foam. The foam can be rigid and also have adhesive properties. The liquified gas used is CF.sub.3 l or mixtures thereof.

  15. Casting an Ecclesiastical Prince: Portrait Medals of Pope Julius II

    E-Print Network [OSTI]

    Fishburne, James Eynon

    2014-01-01

    OF CALIFORNIA Los Angeles Casting an Ecclesiastical Prince:OF THE DISSERTATION Casting an Ecclesiastical Prince:Bramante. 16 In addition to casting medals, he also crafted

  16. Improving the Efficiency of Die Casting Machine Hydraulic Systems with the Retrofit of Adjustable Frequency Drives 

    E-Print Network [OSTI]

    Ambs, L.; Kosanovic, D.; Edberg, C.

    1999-01-01

    this period, the injection plunger is maintaining pressure on the metal in the mold during its solidification. This compensates for shrinkage as the part solidifies. Flow requirements are low while pressure requirements are high. The duration... represents a connected electrical load of over 315 MW. DIE CASTING PROCESS The basic die casting process is very similar to the injection molding process used for fonning plastic parts. Two hardened steel mold or die halves are moved together and a...

  17. Experiments to Populate and Validate a Processing Model for Polyurethane Foam: Additional Data for Structural Foams.

    SciTech Connect (OSTI)

    Rao, Rekha R.; Celina, Mathias C.; Giron, Nicholas Henry; Long, Kevin Nicholas; Russick, Edward M.

    2015-01-01

    We are developing computational models to help understand manufacturing processes, final properties and aging of structural foam, polyurethane PMDI. Th e resulting model predictions of density and cure gradients from the manufacturing process will be used as input to foam heat transfer and mechanical models. BKC 44306 PMDI-10 and BKC 44307 PMDI-18 are the most prevalent foams used in structural parts. Experiments needed to parameterize models of the reaction kinetics and the equations of motion during the foam blowing stages were described for BKC 44306 PMDI-10 in the first of this report series (Mondy et al. 2014). BKC 44307 PMDI-18 is a new foam that will be used to make relatively dense structural supports via over packing. It uses a different catalyst than those in the BKC 44306 family of foams; hence, we expect that the reaction kineti cs models must be modified. Here we detail the experiments needed to characteriz e the reaction kinetics of BKC 44307 PMDI-18 and suggest parameters for the model based on these experiments. In additi on, the second part of this report describes data taken to provide input to the preliminary nonlinear visco elastic structural response model developed for BKC 44306 PMDI-10 foam. We show that the standard cu re schedule used by KCP does not fully cure the material, and, upon temperature elevation above 150 o C, oxidation or decomposition reactions occur that alter the composition of the foam. These findings suggest that achieving a fully cured foam part with this formulation may be not be possible through therma l curing. As such, visco elastic characterization procedures developed for curing thermosets can provide only approximate material properties, since the state of the material continuously evolves during tests.

  18. CTD019Hickey, W8201_casts 19-22 Hickey, W8201_casts 19-22, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    CTD019Hickey, W8201_casts 19-22 Hickey, W8201_casts 19-22, page 1 #12;CTD019Hickey, W8201_casts 19-22 Hickey, W8201_casts 19-22, page 2 #12;CTD019Hickey, W8201_casts 19-22 Hickey, W8201_casts 19-22, page 3 #12;CTD019Hickey, W8201_casts 19-22 Hickey, W8201_casts 19-22, page 4 #12;CTD019Hickey, W8201_casts 19

  19. CTD023Hickey, W8201_casts 23-25 Hickey, W8201_casts 23-25, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    CTD023Hickey, W8201_casts 23-25 Hickey, W8201_casts 23-25, page 1 #12;CTD023Hickey, W8201_casts 23-25 Hickey, W8201_casts 23-25, page 2 #12;CTD023Hickey, W8201_casts 23-25 Hickey, W8201_casts 23-25, page 3 #12;CTD023Hickey, W8201_casts 23-25 Hickey, W8201_casts 23-25, page 4 #12;CTD023Hickey, W8201_casts 23

  20. CTD021Hickey, W8101_casts 21-23 Hickey, W8101_casts 21-23, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    CTD021Hickey, W8101_casts 21-23 Hickey, W8101_casts 21-23, page 1 #12;CTD021Hickey, W8101_casts 21-23 Hickey, W8101_casts 21-23, page 2 #12;CTD021Hickey, W8101_casts 21-23 Hickey, W8101_casts 21-23, page 3 #12;CTD021Hickey, W8101_casts 21-23 Hickey, W8101_casts 21-23, page 4 #12;CTD021Hickey, W8101_casts 21

  1. Factors Contributing to Petroleum Foaming. 2. Synthetic Crude Oil Systems

    E-Print Network [OSTI]

    Kilpatrick, Peter K.

    Factors Contributing to Petroleum Foaming. 2. Synthetic Crude Oil Systems Nael N. Zaki, Michael K to the petroleum industry. Nonaqueous foams occur in the production of and refining of crude oil. Crude oil foams can pose major problems for operators of gas/oil separation plants, causing a loss of crude

  2. Mechanistic Foam Flow Simulation in Heterogeneous and Multidimensional Porous Media

    E-Print Network [OSTI]

    Patzek, Tadeusz W.

    , and thermal reservoir simulator and created a fully functional, mechanistic foam simulator. Because foam, field-scale model for foam displacement is currently in use. The population-balance method for modeling that is analogous to energy and species mass balances7, 8. Accordingly, a separate conservation equation is written

  3. Elastic effects in the foaming of thermoplastics Celeste Sagui,1

    E-Print Network [OSTI]

    Grant, Martin

    . Inside an extruder, the foams are pre- pared by dissolving a small molecular species, such as CO2 , whichElastic effects in the foaming of thermoplastics Celeste Sagui,1 Luc Piche´,1,2 Abdelhadi Sahnoune1063-651X 98 16109-3 PACS number s : 83.80.Bp, 61.25.Hq, 82.70.Rr Polymeric foams have gained

  4. Development of a new casting method to fabricate U–Zr alloy containing minor actinides

    SciTech Connect (OSTI)

    Jong Hwan Kim; Hoon Song; Hyung Tae Kim; Ki Hwan Kim; Chan Bock Lee; R. S. Fielding

    2014-01-01

    Metal fuel slugs of U–Zr alloys for a sodium-cooled fast reactor (SFR) have conventionally been fabricated using an injection casting method. However, casting alloys containing volatile radioactive constituents, such as Am, are problematic in a conventional injection casting method. As an alternative fabrication method, low pressure gravity casting has been developed. Casting soundness, microstructural characteristics, alloying composition, density, and fuel losses were evaluated for the following as-cast fuel slugs: U–10 wt% Zr, U–10 wt% Zr–5 wt% RE, and U–10 wt% Zr–5 wt% RE–5 wt% Mn. The U and Zr contents were uniform throughout the matrix, and impurities such as oxyen, carbon, and nitrogen satisfied the specification of total impurities less than 2,000 ppm. The appearance of the fuel slugs was generally sound, and the internal integrity was shown to be satisfactory based on gamma-ray radiography. In a volatile surrogate casting test, the U–Zr–RE–Mn fuel slug showed that nearly all of the manganese was retained when casting was done under an inert atmosphere.

  5. Experiments for foam model development and validation.

    SciTech Connect (OSTI)

    Bourdon, Christopher Jay; Cote, Raymond O.; Moffat, Harry K.; Grillet, Anne Mary; Mahoney, James F.; Russick, Edward Mark; Adolf, Douglas Brian; Rao, Rekha Ranjana; Thompson, Kyle Richard; Kraynik, Andrew Michael; Castaneda, Jaime N.; Brotherton, Christopher M.; Mondy, Lisa Ann; Gorby, Allen D.

    2008-09-01

    A series of experiments has been performed to allow observation of the foaming process and the collection of temperature, rise rate, and microstructural data. Microfocus video is used in conjunction with particle image velocimetry (PIV) to elucidate the boundary condition at the wall. Rheology, reaction kinetics and density measurements complement the flow visualization. X-ray computed tomography (CT) is used to examine the cured foams to determine density gradients. These data provide input to a continuum level finite element model of the blowing process.

  6. Method of forming a foamed thermoplastic polymer

    DOE Patents [OSTI]

    Duchane, David V. (Los Alamos, NM); Cash, David L. (Los Alamos, NM)

    1986-01-01

    A method of forming a foamed thermoplastic polymer. A solid thermoplastic lymer is immersed in an immersant solution comprising a compatible carrier solvent and an infusant solution containing an incompatible liquid blowing agent for a time sufficient for the immersant solution to infuse into the polymer. The carrier solvent is then selectively extracted, preferably by a solvent exchange process in which the immersant solution is gradually diluted with and replaced by the infusant solution, so as to selectively leave behind the infusant solution permanently entrapped in the polymer. The polymer is then heated to volatilize the blowing agent and expand the polymer into a foamed state.

  7. CAST results and Axion review

    E-Print Network [OSTI]

    T. Geralis; for the CAST collaboration

    2009-05-26

    We present results from the CERN Axion Solar Telescope (CAST) and the Axion Dark Matter eXperiment (ADMX), together with a brief review on prospects on Axion searches with a variety of experimental techniques. CAST has explored masses up to 0.64 eV setting the most stringent limit on the axion-photon coupling, apart for the micro-eV region where ADMX is the most competitive experiment. CAST is aiming at surpassing the 1eV WMAP upper limit and possibly revisiting the operation in vacuum with extra sensitive X-ray detectors, while ADMX, using improved extra sensitive SQUID amplifiers will explore the micro-eV mass range.

  8. Low density microcellular carbon foams and method of preparation

    DOE Patents [OSTI]

    Arnold, C. Jr.; Aubert, J.H.; Clough, R.L.; Rand, P.B.; Sylwester, A.P.

    1988-06-20

    A low density, open-celled microcellular carbon foam is disclosed which is prepared by dissolving a carbonizable polymer or copolymer in a solvent, pouring the solution into a mold, cooling the solution, removing the solvent, and then carbonizing the polymer or copolymer in a high temperature oven to produce the foam. If desired, an additive can be introduced in order to produce a doped carbon foam, and the foams can be made isotropic by selection of a suitable solvent. The low density, microcellular foams produced by this process are particularly useful in the fabrication of inertial confinement fusion targets, but can also be used as catalysts, absorbents, and electrodes.

  9. Low density microcellular carbon foams and method of preparation

    DOE Patents [OSTI]

    Arnold, Jr., Charles (Albuquerque, NM); Aubert, James H. (Albuquerque, NM); Clough, Roger L. (Albuquerque, NM); Rand, Peter B. (Albuquerque, NM); Sylwester, Alan P. (Albuquerque, NM)

    1989-01-01

    A low density, open-celled microcellular carbon foam is disclosed which is prepared by dissolving a carbonizable polymer or copolymer in a solvent, pouring the solution into a mold, cooling the solution, removing the solvent, and then carbonizing the polymer or copolymer in a high temperature oven to produce the foam. If desired, an additive can be introduced in order to produce a doped carbon foam, and the foams can be made isotropic by selection of a suitable solvent. The low density, microcellular foams produced by this process are particularly useful in the fabrication of inertial confinement fusion targets, but can also be used as catalysts, absorbents, and electrodes.

  10. 2005 May JOM 29 Casting DefectsOverview

    E-Print Network [OSTI]

    Beckermann, Christoph

    2005 May · JOM 29 Casting DefectsOverview Casting designs are generally based factors of safety, which leadtoincreasedcomponentweightsand inefficient use of materials. In castings in castings and determine their effect on performance. INTRODUCTION Designers are responsible for the per

  11. Computing and Visualization in Science manuscript No. DOI: 10.1007/s00791-008-0090-4

    E-Print Network [OSTI]

    of applications, such as the optimization of production processes for foam- ing or casting [23], the research algorithm that was developed to simulate metal foams [43]. The approach is similar to volume

  12. Thermo-mechanical characterization of silicone foams

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Rangaswamy, Partha; Smith, Nickolaus A.; Cady, Carl M.; Lewis, Matthew W.

    2015-10-01

    Cellular solids such as elastomeric foams are used in many structural applications to absorb and dissipate energy, due to their light weight (low density) and high energy absorption capability. In this paper we will discuss foams derived from S5370, a silicone foam formulation developed by Dow Corning. In the application presented, the foam is consolidated into a cushion component of constant thickness but variable density. A mechanical material model developed by Lewis (2013), predicts material response, in part, as a function of relative density. To determine the required parameters for this model we have obtained the mechanical response in compressionmore »for ambient, cold and hot temperatures. The variable density cushion provided samples sufficient samples so that the effect of sample initial density on the mechanical response could be studied. The mechanical response data showed extreme sensitivity to relative density. We also observed at strains corresponding to 1 MPa a linear relationship between strain and initial density for all temperatures. Samples taken from parts with a history of thermal cycling demonstrated a stiffening response that was a function of temperature, with the trend of more stiffness as temperature increased above ambient. This observation is in agreement with the entropic effects on the thermo-mechanical behavior of silicone polymers. In this study, we present the experimental methods necessary for the development of a material model, the testing protocol, analysis of test data, and a discussion of load (stress) and gap (strain) as a function of sample initial densities and temperatures« less

  13. Pipe viscometry of foams C. Enzendorfer

    E-Print Network [OSTI]

    Valkó, Peter

    Pipe viscometry of foams C. Enzendorfer Institute of Drilling and Production, Mining University solutions are used widely. They are especially attractive as proppant carrying fluids in hydraulic frac a homogeneous fluid with rheology depending not only on the shear rate but on additional parameters

  14. Casting NETs provides bait for autoantibody-mediated arthritis

    E-Print Network [OSTI]

    Lew, Brian Raymond

    2011-01-01

    OF CALIFORNIA, SAN DIEGO Casting NETs provides bait forvii ABSTRACT OF THE THESIS Casting NETs provides bait for

  15. July/August 20056 Casting aluminum

    E-Print Network [OSTI]

    Colton, Jonathan S.

    July/August 20056 Bob Rapp Casting aluminum Lay people unfamiliar with metallurgical processing to cast Al commercially. Perhaps I can interest the reader with a summary of this important process. I refer to casting large Al shapes suitable for rolling, forging, pressing, extruding, or drawing to make

  16. Master thesis Supercooled Simultaneous Composite Casting

    E-Print Network [OSTI]

    Cambridge, University of

    I Master thesis Supercooled Simultaneous Composite Casting for Microstructure Refinement of AlloySimultaneousCompositeCastingforMicrostructureRefinementofAlloy2008Kim,YongKi #12;3 SupercooledSimultaneousCompositeCasting for Microstructure Refinement of Alloy #12;4 Supercooled Simultaneous Composite Casting for Microstructure Refinement of Alloy by Kim

  17. Simulation of Dimensional Changes in Steel Casting

    E-Print Network [OSTI]

    Beckermann, Christoph

    casting due to thermal effects (temperature differences) and volume changes (e.g., shrinkage, sand are the primary reasons for dimensional changes during casting. In the case such shrinkage is free or unrestrained of the sand and the solidifying steel. Such hindered shrinkage of restrained casting features is usually less

  18. Tape casting of magnesium oxide.

    SciTech Connect (OSTI)

    Ayala, Alicia; Corral, Erica L.; Loehman, Ronald E.; Bencoe, Denise Nora; Reiterer, Markus; Shah, Raja A.

    2008-02-01

    A tape casting procedure for fabricating ceramic magnesium oxide tapes has been developed as a method to produce flat sheets of sintered MgO that are thin and porous. Thickness of single layer tapes is in the range of 200-400 {micro}m with corresponding surface roughness values in the range of 10-20 {micro}m as measured by laser profilometry. Development of the tape casting technique required optimization of pretreatment for the starting magnesium oxide (MgO) powder as well as a detailed study of the casting slurry preparation and subsequent heat treatments for sintering and final tape flattening. Milling time of the ceramic powder, plasticizer, and binder mixture was identified as a primary factor affecting surface morphology of the tapes. In general, longer milling times resulted in green tapes with a noticeably smoother surface. This work demonstrates that meticulous control of the entire tape casting operation is necessary to obtain high-quality MgO tapes.

  19. Hickey, W8009C, casts 992-995 Hickey, W8009C, casts 992-995, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8009C, casts 992-995 Hickey, W8009C, casts 992-995, page 1 #12;Hickey, W8009C, casts 992-995 Hickey, W8009C, casts 992-995, page 2 #12;Hickey, W8009C, casts 992-995 Hickey, W8009C, casts 992-995, page 3 #12;Hickey, W8009C, casts 992-995 Hickey, W8009C, casts 992-995, page 4 #12;Hickey, W8009C

  20. Rapid oxidation/stabilization technique for carbon foams, carbon fibers and C/C composites

    DOE Patents [OSTI]

    Tan, Seng; Tan, Cher-Dip

    2004-05-11

    An enhanced method for the post processing, i.e. oxidation or stabilization, of carbon materials including, but not limited to, carbon foams, carbon fibers, dense carbon-carbon composites, carbon/ceramic and carbon/metal composites, which method requires relatively very short and more effective such processing steps. The introduction of an "oxygen spill over catalyst" into the carbon precursor by blending with the carbon starting material or exposure of the carbon precursor to such a material supplies required oxygen at the atomic level and permits oxidation/stabilization of carbon materials in a fraction of the time and with a fraction of the energy normally required to accomplish such carbon processing steps. Carbon based foams, solids, composites and fiber products made utilizing this method are also described.

  1. Application of a single step temporal imaging of magnetic induction tomography for metal flow visualization

    E-Print Network [OSTI]

    Adler, Andy

    and sensing coils. MIT has potential in visualization of metal flow for continuous casting mainly because of spatio-temporal resolution using the real metal flow in continuous casting. Results are comparedApplication of a single step temporal imaging of magnetic induction tomography for metal flow

  2. Nanoparticle-stabilized CO? foam for CO? EOR application

    SciTech Connect (OSTI)

    Liu, Ning; Lee, Robert; Yu, Jianjia; Li, Liangxiong; Bustamante, Elizabeth; Khalil, Munawar; Mo, Di; Jia, Bao; Wang, Sai; San, Jingshan; An, Cheng

    2015-01-31

    The purpose of this project was to develop nanoparticle-stabilized CO? foam for CO? -EOR application, in which nanoparticles instead of surfactants are used for stabilizing CO? foam to improve the CO? sweep efficiency and increase oil recovery. The studies included: (1) investigation of CO? foam generation nanoparticles, such as silica nanoparticles, and the effects of particle concentration and surface properties, CO?/brine ratio, brine salinity, pressure, and temperature on foam generation and foam stability; (2) coreflooding tests to understand the nanoparticle-stabilized CO? foam for waterflooded residual oil recovery, which include: oil-free coreflooding experiments with nanoparticle-stabilized CO? foam to understand the transportation of nanoparticles through the core; measurements of foam stability and CO? sweep efficiency under reservoir conditions to investigate temperature and pressure effects on the foam performance and oil recovery as well as the sweep efficiency in different core samples with different rock properties; and (3) long-term coreflooding experiments with the nanoparticle- stabilized CO? foam for residual oil recovery. Finally, the technical and economical feasibility of this technology was evaluated.

  3. Prediction of Part Distortion in Die Casting

    SciTech Connect (OSTI)

    R. Allen Miller

    2005-03-30

    The die casting process is one of the net shape manufacturing techniques and is widely used to produce high production castings with tight tolerances for many industries. An understanding of the stress distribution and the deformation pattern of parts produced by die casting will result in less deviation from the part design specification, a better die design and eventually more productivity and cost savings. This report presents methods that can be used to simulate the die casting process in order to predict the deformation and stresses in the produced part and assesses the degree to which distortion modeling is practical for die casting at the current time. A coupled thermal-mechanical finite elements model was used to simulate the die casting process. The simulation models the effect of thermal and mechanical interaction between the casting and the die. It also includes the temperature dependant material properties of the casting. Based on a designed experiment, a sensitivity analysis was conducted on the model to investigate the effect of key factors. These factors include the casting material model, material properties and thermal interaction between casting and dies. To verify the casting distortion predictions, it was compared against the measured dimensions of produced parts. The comparison included dimensions along and across the parting plane and the flatness of one surface.

  4. Computer modeling of electromagnetic edge containment in twin-roll casting

    SciTech Connect (OSTI)

    Chang, F.C.; Turner, L.R.; Hull, J.R.; Wang, Y.H.; Blazek, K.E.

    1998-07-01

    This paper presents modeling studies of magnetohydrodynamics (MHD) analysis in twin-roll casting. Argonne National Laboratory (ANL) and Inland Steel Company have worked together to develop a 3-D computer model that can predict eddy currents, fluid flows, and liquid metal containment for an electromagnetic (EM) edge containment device. This mathematical model can greatly shorten casting research on the use of EM fields for liquid metal containment and control. It can also optimize the existing casting processes and minimize expensive, time-consuming full-scale testing. The model was verified by comparing predictions with experimental results of liquid-metal containment and fluid flow in EM edge dams designed at Inland Steel for twin-roll casting. Numerical simulation was performed by coupling a three-dimensional (3-D) finite-element EM code (ELEKTRA) and a 3-D finite-difference fluids code (CaPS-EM) to solve Maxwell`s equations, Ohm`s law, Navier-Stokes equations, and transport equations of turbulence flow in a casting process that uses EM fields. ELEKTRA is able to predict the eddy-current distribution and electromagnetic forces in complex geometry. CaPS-EM is capable of modeling fluid flows with free-surfaces and dynamic rollers. The computed 3-D magnetic fields and induced eddy currents in ELEKTRA are used as input to flow-field computations in CaPS-EM. Results of the numerical simulation compared well with measurements obtained from both static and dynamic tests.

  5. Hickey, W8009C, casts 1-9 Hickey, W8009C, casts 1-9, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8009C, casts 1-9 Hickey, W8009C, casts 1-9, page 1 #12;Hickey, W8009C, casts 1-9 Hickey, W8009C, casts 1-9, page 2 #12;Hickey, W8009C, casts 1-9 Hickey, W8009C, casts 1-9, page 3 #12;Hickey, W8009C, casts 1-9 Hickey, W8009C, casts 1-9, page 4 #12;Hickey, W8009C, casts 1-9 Hickey, W8009C, casts

  6. Military housing foam application and analysis

    SciTech Connect (OSTI)

    Torres, J. J.

    2012-03-01

    Sandia and Forest City have established a Cooperative Research and Development Agreement (CRADA), the partnership provides a unique opportunity to take technology research and development from demonstration to application in sustainable communities. This project consists of two activities conducted in Hawaii that focus on performance, integration and application of energy saving technologies. Hawaii has many energy challenges, making this location an excellent testbed for these activities. Under this project, spray foam technology was applied at military housing on Oahu and the consumption data collected. A cost benefit and operational analysis of the foam was completed. The second phase of this project included design, integration, and analysis of photovoltaic systems at a military community on Oahu. This phase of the project was conducted as part of Forest City's second Solar America Showcase Award.

  7. Osmotic Stabilisation of Concentrated Emulsions and Foams

    E-Print Network [OSTI]

    A. J. Webster; M. E. Cates

    2001-01-19

    In the absence of coalescence, coarsening of emulsions (and foams) is controlled by molecular diffusion of dispersed phase between droplets/bubbles. Studies of dilute emulsions have shown how the osmotic pressure of a trapped species within droplets can ``osmotically stabilise'' the emulsion. Webster and Cates (Langmuir, 1998, 14, 2068-2079) gave rigorous criteria for osmotic stabilisation of mono- and polydisperse emulsions, in the dilute regime. We consider here whether analogous criteria exist for the osmotic stabilisation of mono- and polydisperse concentrated emulsions and foams, and suggest that the pressure differences driving coarsening are small compared to the mean Laplace pressure. An exact calculation confirms this for a monodisperse 2D model, finding a bubble's pressure as P_i = P + Pi + P_i^G, with P, Pi the atmospheric and osmotic pressures, and P_i^G a ``geometric pressure'' that reduces to the Laplace pressure only for a spherical bubble. For Princen's 2D emulsion model, P_i^G is only 5% larger in the dry limit than the dilute limit. We conclude that osmotic stabilisation of dense systems typically requires a pressure of trapped molecules in each droplet that is comparable to the Laplace pressures the same droplets would have if spherical, as opposed to the much larger Laplace pressures present in the system. We study coarsening of foams and concentrated emulsions when there is insufficient of the trapped species present. Rate-limiting mechanisms are considered, their applicability and associated droplet growth rates discussed. In a concentrated foam or emulsion, a finite yield threshold for droplet rearrangement may be enough to prevent coarsening of the remainder.

  8. ENHANCEMENT OF STRUCTURAL FOAM MATERIALS BY INCORPORATION OF GASIFIER SLAG

    SciTech Connect (OSTI)

    Olin Perry Norton; Ronald A. Palmer; W. Gene Ramsey

    2006-03-15

    As advanced gasification technology is increasingly adopted as an energy source, disposal of the resulting slag will become a problem. We have shown that gasifier slag can be incorporated into foamed glass, which is currently being manufactured as an abrasive and as an insulating material. The slag we add to foamed glass does not simply act as filler, but improves the mechanical properties of the product. Incorporation of gasifier slag can make foamed glass stronger and more abrasion resistant.

  9. Hyper-dendritic nanoporous zinc foam anodes

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Chamoun, Mylad; Hertzberg, Benjamin J.; Gupta, Tanya; Davies, Daniel; Bhadra, Shoham; Van Tassell, Barry.; Erdonmez, Can; Steingart, Daniel A.

    2015-04-24

    The low cost, significant reducing potential, and relative safety of the zinc electrode is a common hope for a reductant in secondary batteries, but it is limited mainly to primary implementation due to shape change. In this work we exploit such shape change for the benefit of static electrodes through the electrodeposition of hyper-dendritic nanoporous zinc foam. Electrodeposition of zinc foam resulted in nanoparticles formed on secondary dendrites in a three-dimensional network with a particle size distribution of 54.1 - 96.0 nm. The nanoporous zinc foam contributed to highly oriented crystals, high surface area and more rapid kinetics in contrastmore »to conventional zinc in alkaline mediums. The anode material presented had a utilization of ~ 88% at full depth-of-discharge at various rates indicating a superb rate-capability. The rechargeability of Zn?/Zn²? showed significant capacity retention over 100 cycles at a 40% depth-of-discharge to ensure that the dendritic core structure was imperforated. The dendritic architecture was densified upon charge-discharge cycling and presented superior performance compared to bulk zinc electrodes.« less

  10. Hyper-dendritic nanoporous zinc foam anodes

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Chamoun, Mylad [Brookhaven National Lab. (BNL), Upton, NY (United States); Hertzberg, Benjamin J. [Princeton Univ., NJ (United States); Gupta, Tanya [Princeton Univ., NJ (United States); Davies, Daniel [Princeton Univ., NJ (United States); Bhadra, Shoham [Princeton Univ., NJ (United States); Van Tassell, Barry. [City College of New York, NY (United States); Erdonmez, Can [Brookhaven National Lab. (BNL), Upton, NY (United States); Steingart, Daniel A. [Princeton Univ., NJ (United States)

    2015-04-24

    The low cost, significant reducing potential, and relative safety of the zinc electrode is a common hope for a reductant in secondary batteries, but it is limited mainly to primary implementation due to shape change. In this work we exploit such shape change for the benefit of static electrodes through the electrodeposition of hyper-dendritic nanoporous zinc foam. Electrodeposition of zinc foam resulted in nanoparticles formed on secondary dendrites in a three-dimensional network with a particle size distribution of 54.1 - 96.0 nm. The nanoporous zinc foam contributed to highly oriented crystals, high surface area and more rapid kinetics in contrast to conventional zinc in alkaline mediums. The anode material presented had a utilization of ~ 88% at full depth-of-discharge at various rates indicating a superb rate-capability. The rechargeability of Zn?/Zn²? showed significant capacity retention over 100 cycles at a 40% depth-of-discharge to ensure that the dendritic core structure was imperforated. The dendritic architecture was densified upon charge-discharge cycling and presented superior performance compared to bulk zinc electrodes.

  11. Foaming characteristics of refigerant/lubricant mixtures

    SciTech Connect (OSTI)

    Goswami, D.Y.; Shah, D.O.; Jotshi, C.K.; Bhagwat, S.; Leung, M.; Gregory, A.

    1997-04-01

    The air-conditioning and refrigeration industry has moved to HFC refrigerants which have zero ozone depletion and low global warming potential due to regulations on CFC and HCFC refrigerants and concerns for the environment. The change in refrigerants has prompted the switch from mineral oil and alkylbenzene lubricants to polyolester-based lubricants. This change has also brought about a desire for lubricant, refrigerant and compressor manufacturers to understand the foaming properties of alternative refrigerant/ lubricant mixtures, as well as the mechanisms which affect these properties. The objectives of this investigation are to experimentally determine the foaming absorption and desorption rates of HFC and blended refrigerants in polyolester lubricant and to define the characteristics of the foam formed when the refrigerant leaves the refrigerant/ lubricant mixture after being exposed to a pressure drop. The refrigerants being examined include baseline refrigerants: CFC-12 (R-12) and HCFC-22 (R-22); alternative refrigerants: HFC-32 (R-32), R-125, R-134a, and R-143a; and blended refrigerants: R-404A, R-407C, and R-410A. The baseline refrigerants are tested with ISO 32 (Witco 3GS) and ISO 68 (4GS) mineral oils while the alternative and blended refrigerants are tested with two ISO 68 polyolesters (Witco SL68 and ICI RL68H).

  12. Tissue Magnetic Susceptibility Matched Pyrolytic Graphite Foam for Improved MRI

    E-Print Network [OSTI]

    Lee, Gary Chiaray

    2011-01-01

    on a ZPrinter Model 150 3D printer (ZCorp, Burlington, MA),PG foam neck cushions. A 3D printer was used to create the

  13. Evaluation of biodegradation potential of foam embedded Burkholderia cepacia

    E-Print Network [OSTI]

    Hazen, Terry

    of contaminated ground- waters. Materials and methods Bacterial growth conditions and foam preparation Axenic to degrade pollutants like aromatic hydrocarbons and chlorinated solvents (Fol- som and Chapman, 1991

  14. Unified Creep Plasticity Damage (UCPD) Model for Rigid Polyurethane Foams.

    SciTech Connect (OSTI)

    Neilsen, Michael K.; Lu, Wei-Yang; Scherzinger, William M.; Hinnerichs, Terry D.; Lo, Chi S.

    2015-06-01

    Numerous experiments were performed to characterize the mechanical response of several different rigid polyurethane foams (FR3712, PMDI10, PMDI20, and TufFoam35) to large deformation. In these experiments, the effects of load path, loading rate, and temperature were investigated. Results from these experiments indicated that rigid polyurethane foams exhibit significant volumetric and deviatoric plasticity when they are compressed. Rigid polyurethane foams were also found to be very strain-rate and temperature dependent. These foams are also rather brittle and crack when loaded to small strains in tension or to larger strains in compression. Thus, a new Unified Creep Plasticity Damage (UCPD) model was developed and implemented into SIERRA with the name Foam Damage to describe the mechanical response of these foams to large deformation at a variety of temperatures and strain rates. This report includes a description of recent experiments and experimental findings. Next, development of a UCPD model for rigid, polyurethane foams is described. Selection of material parameters for a variety of rigid polyurethane foams is then discussed and finite element simulations with the new UCPD model are compared with experimental results to show behavior that can be captured with this model.

  15. FOAM (Functional Ontology Assignments for Metagenomes): A Hidden...

    Office of Scientific and Technical Information (OSTI)

    Ontology Assignments for Metagenomes): A Hidden Markov Model (HMM) database with environmental focus Citation Details In-Document Search Title: FOAM (Functional Ontology...

  16. Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Clean Steel Casting Production

    SciTech Connect (OSTI)

    Kuyucak, Selcuk; Li, Delin

    2013-12-31

    Inclusions in steel castings can cause rework, scrap, poor machining, and reduced casting performance, which can obviously result in excess energy consumption. Significant progress in understanding inclusion source, formation and control has been made. Inclusions can be defined as non-metallic materials such as refractory, sand, slag, or coatings, embedded in a metallic matrix. This research project has focused on the mold filling aspects to examine the effects of pouring methods and gating designs on the steel casting cleanliness through water modeling, computer modeling, and melting/casting experiments. Early in the research project, comprehensive studies of bottom-pouring water modeling and low-alloy steel casting experiments were completed. The extent of air entrainment in bottom-poured large castings was demonstrated by water modeling. Current gating systems are designed to prevent air aspiration. However, air entrainment is equally harmful and no prevention measures are in current practice. In this study, new basin designs included a basin dam, submerged nozzle, and nozzle extension. The entrained air and inclusions from the gating system were significantly reduced using the new basin method. Near the end of the project, there has been close collaboration with Wescast Industries Inc., a company manufacturing automotive exhaust components. Both computer modeling using Magma software and melting/casting experiments on thin wall turbo-housing stainless steel castings were completed in this short period of time. Six gating designs were created, including the current gating on the pattern, non-pressurized, partially pressurized, naturally pressurized, naturally pressurized without filter, and radial choke gating without filter, for Magma modeling. The melt filling velocity and temperature were determined from the modeling. Based on the simulation results, three gating designs were chosen for further melting and casting experiments on the same casting pattern using the lip pouring method. It was observed again that gating designs greatly influenced the melt filling velocity and the number of inclusion defects. The radial choked gating showed improvements in casting cleanliness and yield over the other gatings, even though no mold filters were used in the gating system.

  17. Low-head feeding system for thin section castings

    DOE Patents [OSTI]

    Daniel, Sabah S. (Allegheny County, PA); Kleeb, Thomas R. (Allegheny County, PA); Lewis, Thomas W. (Allegheny County, PA); McDermott, John F. (Allegheny County, PA); Ozgu, Mustafa R. (Northhampton County, PA); Padfield, Ralph C. (Lehigh County, PA); Rego, Donovan N. (Lehigh County, PA); Vassilicos, Achilles (Allegheny County, PA)

    1990-01-01

    A feed system is provided for conveying molten metal to a thin section caster having mold surfaces moving exclusively in the direction of casting. The feed system has a passage of circular cross section adjacent to one end thereof for receiving molten metal and a rectangular cross section at the delivery end thereof adjacent to the caster. The feed system is designed for supplying molten metal to the caster at low pressure for "closed-pool" type caster operation. The point of highest elevation in the metal flow passage of the feed system is on the upper surface of a transition portion where the cross section changes from circular to rectangular adjacent to the nozzle. The level or height of the high point above the centerline of the nozzle exit is selected so as to be less than the pressure of the metal measured in inches at the nozzle exit. This feature enables the maintenance of positive pressure in the metal within the feed system so that ingress of air into the metal is prevented.

  18. Show me the (shortest) way to go home Foams, soap films and minimization

    E-Print Network [OSTI]

    Cox, Simon

    importance: · Oil recovery · Car manufacture · (Industrial) cleaning · Fire-fighting · Ore separation · Personal Care · Food products Why are foams of interest? foams@aber.ac.uk #12;

  19. polyurethane foam Goods, S.H.; Neuschwanger, C.L.; Henderson...

    Office of Scientific and Technical Information (OSTI)

    Mechanical properties and energy absorption characteristics of a polyurethane foam Goods, S.H.; Neuschwanger, C.L.; Henderson, C.; Skala, D.M. 36 MATERIALS SCIENCE; FOAMS;...

  20. Gating of Permanent Molds for ALuminum Casting

    SciTech Connect (OSTI)

    David Schwam; John F. Wallace; Tom Engle; Qingming Chang

    2004-03-30

    This report summarizes a two-year project, DE-FC07-01ID13983 that concerns the gating of aluminum castings in permanent molds. The main goal of the project is to improve the quality of aluminum castings produced in permanent molds. The approach taken was determine how the vertical type gating systems used for permanent mold castings can be designed to fill the mold cavity with a minimum of damage to the quality of the resulting casting. It is evident that somewhat different systems are preferred for different shapes and sizes of aluminum castings. The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. The project highlights the characteristic features of gating systems used in permanent mold aluminum foundries and recommends gating procedures designed to avoid common defects. The study also provides direct evidence on the filling pattern and heat flow behavior in permanent mold castings.

  1. Measurement and Simulation of Distortion of a Steel Bracket Casting D. Galles and C. Beckermann

    E-Print Network [OSTI]

    Beckermann, Christoph

    are strongly correlated to the thermal expansion of the core, additional research of the mold properties create interactions at the mold- metal interface and generate stresses. These stresses induce mechanical-solid mushy zone3 . Distortions and defects compromise the quality of the casting and may require costly, time

  2. A Benchmark Study on Casting Residual Stress

    SciTech Connect (OSTI)

    Johnson, Eric M. [John Deere -- Moline Tech Center; Watkins, Thomas R [ORNL; Schmidlin, Joshua E [ORNL; Dutler, S. A. [MAGMA Foundry Technologies, Inc.

    2012-01-01

    Stringent regulatory requirements, such as Tier IV norms, have pushed the cast iron for automotive applications to its limit. The castings need to be designed with closer tolerances by incorporating hitherto unknowns, such as residual stresses arising due to thermal gradients, phase and microstructural changes during solidification phenomenon. Residual stresses were earlier neglected in the casting designs by incorporating large factors of safety. Experimental measurement of residual stress in a casting through neutron or X-ray diffraction, sectioning or hole drilling, magnetic, electric or photoelastic measurements is very difficult and time consuming exercise. A detailed multi-physics model, incorporating thermo-mechanical and phase transformation phenomenon, provides an attractive alternative to assess the residual stresses generated during casting. However, before relying on the simulation methodology, it is important to rigorously validate the prediction capability by comparing it to experimental measurements. In the present work, a benchmark study was undertaken for casting residual stress measurements through neutron diffraction, which was subsequently used to validate the accuracy of simulation prediction. The stress lattice specimen geometry was designed such that subsequent castings would generate adequate residual stresses during solidification and cooling, without any cracks. The residual stresses in the cast specimen were measured using neutron diffraction. Considering the difficulty in accessing the neutron diffraction facility, these measurements can be considered as benchmark for casting simulation validations. Simulations were performed using the identical specimen geometry and casting conditions for predictions of residual stresses. The simulation predictions were found to agree well with the experimentally measured residual stresses. The experimentally validated model can be subsequently used to predict residual stresses in different cast components. This enables incorporation of the residual stresses at the design phase along with external loads for accurate predictions of fatigue and fracture performance of the cast components.

  3. Casting an Object with a Core Hee-Kap Ahn

    E-Print Network [OSTI]

    Cheng, Siu-Wing

    Casting an Object with a Core Hee-Kap Ahn Sang Won Bae Siu-Wing Cheng Kyung-Yong Chwa Abstract This paper addresses geometric problems that concern manufacturing an object using a cast with a core. In casting, molten material is poured into the cavity of the cast and allowed to solidify. The cast has two

  4. Development of NZP ceramic based {open_quotes}cast-in-place{close_quotes} diesel engine port liners

    SciTech Connect (OSTI)

    Nagaswaran, R.; Limaye, S.Y.

    1996-02-01

    BSX (Ba{sub 1+x}Zr{sub 4}P{sub 6-2x}Si{sub 2x}O{sub 24}) and CSX (Ca{sub l-x}Sr{sub x}Zr{sub 4}P{sub 6}O{sub 24}) type NZP ceramics were fabricated and characterized for: (i) thermal properties viz., thermal conductivity, thermal expansion, thermal stability and thermal shock resistance; (ii) mechanical properties viz., flexure strength and elastic modulus; and (iii) microstructures. Results of these tests and analysis indicated that the BS-25 (x=0.25 in BSX) and CS-50 (x=0.50 in CSX) ceramics had the most desirable properties for casting metal with ceramic in place. Finite element analysis (FEA) of metal casting (with ceramic in place) was conducted to analyze thermomechanical stresses generated and determine material property requirements. Actual metal casting trials were also conducted to verify the results of finite element analysis. In initial trials, the ceramic cracked because of the large thermal expansion mismatch (hoop) stresses (predicted by FEA also). A process for introduction of a compliant layer between the metal and ceramic to alleviate such destructive stresses was developed. The compliant layer was successful in preventing cracking of either the ceramic or the metal. In addition to these achievements, pressure slip casting and gel-casting processes for fabrication of NZP components; and acoustic emission and ultrasonics-based NDE techniques for detection of microcracks and internal flaws, respectively, were successfully developed.

  5. ROLE OF MANGANESE REDUCTION/OXIDATION (REDOX) ON FOAMING AND MELT RATE IN HIGH LEVEL WASTE (HLW) MELTERS (U)

    SciTech Connect (OSTI)

    Jantzen, C; Michael Stone, M

    2007-03-30

    High-level nuclear waste is being immobilized at the Savannah River Site (SRS) by vitrification into borosilicate glass at the Defense Waste Processing Facility (DWPF). Control of the Reduction/Oxidation (REDOX) equilibrium in the DWPF melter is critical for processing high level liquid wastes. Foaming, cold cap roll-overs, and off-gas surges all have an impact on pouring and melt rate during processing of high-level waste (HLW) glass. All of these phenomena can impact waste throughput and attainment in Joule heated melters such as the DWPF. These phenomena are caused by gas-glass disequilibrium when components in the melter feeds convert to glass and liberate gases such as H{sub 2}O vapor (steam), CO{sub 2}, O{sub 2}, H{sub 2}, NO{sub x}, and/or N{sub 2}. During the feed-to-glass conversion in the DWPF melter, multiple types of reactions occur in the cold cap and in the melt pool that release gaseous products. The various gaseous products can cause foaming at the melt pool surface. Foaming should be avoided as much as possible because an insulative layer of foam on the melt surface retards heat transfer to the cold cap and results in low melt rates. Uncontrolled foaming can also result in a blockage of critical melter or melter off-gas components. Foaming can also increase the potential for melter pressure surges, which would then make it difficult to maintain a constant pressure differential between the DWPF melter and the pour spout. Pressure surges can cause erratic pour streams and possible pluggage of the bellows as well. For these reasons, the DWPF uses a REDOX strategy and controls the melt REDOX between 0.09 {le} Fe{sup 2+}/{summation}Fe {le} 0.33. Controlling the DWPF melter at an equilibrium of Fe{sup +2}/{summation}Fe {le} 0.33 prevents metallic and sulfide rich species from forming nodules that can accumulate on the floor of the melter. Control of foaming, due to deoxygenation of manganic species, is achieved by converting oxidized MnO{sub 2} or Mn{sub 2}O{sub 3} species to MnO during melter preprocessing. At the lower redox limit of Fe{sup +2}/{summation}Fe {approx} 0.09 about 99% of the Mn{sup +4}/Mn{sup +3} is converted to Mn{sup +2}. Therefore, the lower REDOX limits eliminates melter foaming from deoxygenation.

  6. A vibrating razor blade machining tool for material removal on low- density foams

    SciTech Connect (OSTI)

    Hillyer, D.F. Jr.

    1990-10-01

    The Lawrence Livermore National Laboratory (LLNL) has developed an accurate method of machining low-density foams into rectangular blank shapes by using a commercial oscillating razor blade machining tool concept marketed as a Vibratome. Since 1970, Vibratome has been used by medical laboratories to section fresh or fixed animal and plant tissues without freezing or embedding. By employing a vibrating razor blade principle, Vibratome sectioning avoids the alteration of morphology and the destruction of enzyme activities. The patented vibrating blade principle moves the sectioning razor blade in a reciprocating arcuate path as it penetrates the specimen. Sectioning takes place in a liquid bath using an ordinary injector-type razor blade. Although other commercial products may accomplish the same task, the Vibratome concept is currently being used at LLNL to obtain improved foam surface qualities from razor machining by combining state-of-the-art air bearing hardware with precise linear motion and an electrodynamic exciter that generates sinusoidal excitation. Razor cut foam surfaces of less than 25 {mu}m (0.001 in.) flatness are achieved over areas of 8.75 in.{sup 2} (2.5 {times} 3.5 in.). Razor machining of wide or narrow foam surfaces is generally characterized by a continuous curl chip for the full length of the material removed. This continuous chip facilitates flatness and prevents increased surface densities caused by material chip collection often left in the surface cells by conventional machine tools. This report covers the design evolution of razor machining of non-metallic soft materials. Hardware that maintains close dimensional tolerances and concurrently leaves the machined surface free of physical property changes is described. 20 figs.

  7. Milling of Sand Blocks to Make Casting Moulds

    SciTech Connect (OSTI)

    Lopez de Lacalle, L. N.; Rodriguez, A.; Lamikiz, A.; Penafiel, F. J. [Department of Mechanical Engineering, University of the Basque Country, ETSII, c/Alameda de Urquijo s/n, 48013 Bilbao (Spain)

    2011-01-17

    In this paper a full procedure to make moulds in sand for direct casting of metallic parts is presented. The technology aims at unique pieces or art pieces, where only one prototype or components is required, but lead times are much reduced. The key of the procedure is to achieve enough tool life when milling with carbide tools, avoiding the risk of sand destruction or damage.The use of inverse techniques is a common input due to the industrial sectors where the direct milling is interesting. Two examples of moulds are presented, evaluating times and costs. A special study of tool wear is also presented.

  8. Hickey, W8010A casts 1-6 Hickey, W8010A casts 1-6, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8010A casts 1-6 Hickey, W8010A casts 1-6, page 1 CTD001 #12;Hickey, W8010A casts 1-6 Hickey, W8010A casts 1-6, page 2 CTD001 #12;Hickey, W8010A casts 1-6 Hickey, W8010A casts 1-6, page 3 CTD001 #12;Hickey, W8010A casts 1-6 Hickey, W8010A casts 1-6, page 4 CTD001 #12;Hickey, W8010A casts 1

  9. In-situ conditioning of a strip casting roll

    DOE Patents [OSTI]

    Williams, Robert S. (Fairfield, OH); Campbell, Steven L. (Middletown, OH)

    1997-01-01

    A strip caster (10) for producing a continuous strip (24) has a tundish (12) for containing a melt (14) and a pair of horizontally disposed water cooled casting rolls (22). The casting rolls are juxtaposed relative to one another for forming a pouring basin (18) for receiving the melt through a teeming tube (16) thereby establishing a meniscus (20) between the rolls for forming a strip (24). The melt is protected from the outside air by a non-oxidizing gas passed through a supply line (28) to a sealing chamber (26). Devices (29) for conditioning the outer peripheral chill surfaces of the casting rolls includes grit blasting nozzles (30A, 30B, 30C, 30D), a collection trough (32) for gathering the grit, a line (34) for recycling the grit to a bag house (36), a feeder (38) and a pressurized distributor (40) for delivering the grit to the nozzles. The conditioning nozzles remove dirt, metal oxides and surface imperfections providing a clean surface readily wetted by the melt.

  10. In-situ conditioning of a strip casting roll

    DOE Patents [OSTI]

    Williams, R.S.; Campbell, S.L.

    1997-07-29

    A strip caster (10) for producing a continuous strip (24) has a tundish (12) for containing a melt (14) and a pair of horizontally disposed water cooled casting rolls (22). The casting rolls are juxtaposed relative to one another for forming a pouring basin (18) for receiving the melt through a teeming tube (16) thereby establishing a meniscus (20) between the rolls for forming a strip (24). The melt is protected from the outside air by a non-oxidizing gas passed through a supply line (28) to a sealing chamber (26). Devices (29) for conditioning the outer peripheral chill surfaces of the casting rolls includes grit blasting nozzles (30A, 30B, 30C, 30D), a collection trough (32) for gathering the grit, a line (34) for recycling the grit to a bag house (36), a feeder (38) and a pressurized distributor (40) for delivering the grit to the nozzles. The conditioning nozzles remove dirt, metal oxides and surface imperfections providing a clean surface readily wetted by the melt.

  11. Fastcast: Integration and application of rapid prototyping and computational simulation to investment casting

    SciTech Connect (OSTI)

    Maguire, M.C.; Baldwin, M.D.; Atwood, C.L.

    1996-09-01

    The emergence of several rapid prototyping and manufacturing (RP and M) technologies is having a dramatic impact on investment casting. While the most successful of the rapid prototyping technologies are almost a decade old, relatively recent process advances in their application have produced some remarkable success in utilizing their products as patterns for investment castings. Sandia National Laboratories has been developed highly coupled experimental and computational capabilities to examine the investment casting process with the intention of reducing the amount of time required to manufacture castings, and to increase the quality of the finished product. This presentation will begin with process aspects of RP and M pattern production and handling, shell fabrication, burnout, and casting. The emphasis will be on how the use of Stereolithography (SL) or Selective Laser Sintered (SLS) patterns differs from more traditional wax pattern processes. Aspects of computational simulation to couple design, thermal analysis, and mold filling will be discussed. Integration of these topics is probably the greatest challenge to the use of concurrent engineering principles with investment casting. Sandia has conducted several experiments aimed at calibrating computer codes and providing data for input into these simulations. Studies involving materials as diverse as stainless steel and gold have been conducted to determine liquid metal behavior in molds via real time radiography. The application of these experiments to predictive simulations will be described.

  12. CAST RESEARCH COMMITTEE Membership: 7 appointed faculty and the CAST Associate Dean for Research

    E-Print Network [OSTI]

    Branoff, Theodore J.

    CAST RESEARCH COMMITTEE Membership: 7 appointed faculty and the CAST Associate Dean for Research and experience researcher. The Associate Dean for Research chairs the Committee and serves an ex officio member board to the Associate Dean for Research in the evaluation and formation of CAST policies related

  13. Pitch-based carbon foam and composites and uses thereof

    DOE Patents [OSTI]

    Klett, James W.; Burchell, Timothy D.; Choudhury, Ashok

    2004-01-06

    A thermally conductive carbon foam is provided, normally having a thermal conductivity of at least 40 W/m.multidot.K. The carbon foam usually has a specific thermal conductivity, defined as the thermal conductivity divided by the density, of at least about 75 W.multidot.cm.sup.3 /m.multidot..degree.K.multidot.gm. The foam also has a high specific surface area, typically at least about 6,000 m.sup.2 /m.sup.3. The foam is characterized by an x-ray diffraction pattern having "doublet" 100 and 101 peaks characterized by a relative peak split factor no greater than about 0.470. The foam is graphitic and exhibits substantially isotropic thermal conductivity. The foam comprises substantially ellipsoidal pores and the mean pore diameter of such pores is preferably no greater than about 340 microns. Other materials, such as phase change materials, can be impregnated in the pores in order to impart beneficial thermal properties to the foam. Heat exchange devices and evaporatively cooled heat sinks utilizing the foams are also disclosed.

  14. Sandia-Power Surety Task Force Hawaii foam analysis.

    SciTech Connect (OSTI)

    McIntyre, Annie

    2010-11-01

    The Office of Secretary of Defense (OSD) Power Surety Task Force was officially created in early 2008, after nearly two years of work in demand reduction and renewable energy technologies to support the Warfighter in Theater. The OSD Power Surety Task Force is tasked with identifying efficient energy solutions that support mission requirements. Spray foam insulation demonstrations were recently expanded beyond field structures to include military housing at Ft. Belvoir. Initial results to using the foam in both applications are favorable. This project will address the remaining key questions: (1) Can this technology help to reduce utility costs for the Installation Commander? (2) Is the foam cost effective? (3) What application differences in housing affect those key metrics? The critical need for energy solutions in Hawaii and the existing relationships among Sandia, the Department of Defense (DOD), the Department of Energy (DOE), and Forest City, make this location a logical choice for a foam demonstration. This project includes application and analysis of foam to a residential duplex at the Waikulu military community on Oahu, Hawaii, as well as reference to spray foam applied to a PACOM facility and additional foamed units on Maui, conducted during this project phase. This report concludes the analysis and describes the utilization of foam insulation at military housing in Hawaii and the subsequent data gathering and analysis.

  15. Carbon 41 (2003) 11751180 Thermomechanical behavior of a graphite foam

    E-Print Network [OSTI]

    Chung, Deborah D.L.

    2003-01-01

    vehicle radiators, satellite panels, heat exchangers for the low density of 0.5 g/cm , the specific), 0.15 for flexible graphite and 0.22 for PTFE. The loss tangent of the graphite foam decreased strain in the graphite foam upon heating and subsequent cooling, such that the thermal expansion

  16. Factors Contributing to Petroleum Foaming. 1. Crude Oil Systems

    E-Print Network [OSTI]

    Kilpatrick, Peter K.

    by unwanted foaming. To study this phenomenon, 20 crude oils were subjected to low-pressure foaming volume, not collapse slope, strongly related to crude oil surface tension. For low asphaltenic crudes the production of crude oil and gas is the high pressure separator, often followed by one or more separators

  17. Pitch-based carbon foam and composites and use thereof

    DOE Patents [OSTI]

    Klett, James W.; Burchell, Timothy D.; Choudhury, Ashok

    2006-07-04

    A thermally conductive carbon foam is provided, normally having a thermal conductivity of at least 40 W/mK. The carbon foam usually has a specific thermal conductivity, defined as the thermal conductivity divided by the density, of at least about 75 Wcm.sup.3/m.degree. Kgm. The foam also has a high specific surface area, typically at least about 6,000 m.sup.2/m.sup.3. The foam is characterized by an x-ray diffraction pattern having "doublet" 100 and 101 peaks characterized by a relative peak split factor no greater than about 0.470. The foam is graphitic and exhibits substantially isotropic thermal conductivity. The foam comprises substantially ellipsoidal pores and the mean pore diameter of such pores is preferably no greater than about 340 microns. Other materials, such as phase change materials, can be impregnated in the pores in order to impart beneficial thermal properties to the foam. Heat exchange devices and evaporatively cooled heat sinks utilizing the foams are also disclosed.

  18. Recovery of flexible polyurethane foam from shredder residue.

    SciTech Connect (OSTI)

    Daniels, E. J.; Jody, b. J.

    1999-06-29

    Argonne National Laboratory has developed a patented, continuous process for the recovery of flexible polyurethane foam (PUF) from auto shredder residue (ASR). To test the process, Argonne researchers conceived of, designed, and built a continuous foam washing and drying system that was pilot-tested at a shredder facility for six months. Economic analysis of the process, using manufacturers' quotes and operating data from Argonne's pilot plant, indicates a payback of less than two years for a plant producing about 1,000 ton/yr of foam. Samples of clean foam were shipped to three major foam reprocessors; all three indicated that the quality of the PUF recovered by the Argonne process met their requirements. Tests of the recovered foam by an independent testing laboratory showed that the recycled foam met the specifications for several automotive applications, including carpet padding, headliner, and sound-suppression support materials. Recovery of foam reduces the mass and the volume of material going to the landfill by about 5% and 30%, respectively. Annually, recovery will save about 1.2 x 10{sup 12} Btu of energy, cut the amount of solid waste being landfilled by about 150,000 tons, and eliminate the emission of about 250 tons of volatile organic compounds (VOCs) into the air.

  19. Yield Improvement in Steel Casting (Yield II)

    SciTech Connect (OSTI)

    Richard A. Hardin; Christoph Beckermann; Tim Hays

    2002-02-18

    This report presents work conducted on the following main projects tasks undertaken in the Yield Improvement in Steel Casting research program: Improvement of Conventional Feeding and Risering Methods, Use of Unconventional Yield Improvement Techniques, and Case Studies in Yield Improvement. Casting trials were conducted and then simulated using the precise casting conditions as recorded by the participating SFSA foundries. These results present a statistically meaningful set of experimental data on soundness versus feeding length. Comparisons between these casting trials and casting trials performed more than forty years ago by Pellini and the SFSA are quite good and appear reasonable. Comparisons between the current SFSA feeding rules and feeding rules based on the minimum Niyama criterion reveal that the Niyama-based rules are generally less conservative. The niyama-based rules also agree better with both the trials presented here, and the casting trails performed by Pellini an d the SFSA years ago. Furthermore, the use of the Niyama criterion to predict centerline shrinkage for horizontally fed plate sections has a theoretical basis according to the casting literature reviewed here. These results strongly support the use of improved feeding rules for horizontal plate sections based on the Niyama criterion, which can be tailored to the casting conditions for a given alloy and to a desired level of soundness. The reliability and repeatability of ASTM shrinkage x-ray ratings was investigated in a statistical study performed on 128 x-rays, each of which were rated seven different times. A manual ''Feeding and Risering Guidelines for Steel Castings' is given in this final report. Results of casting trials performed to test unconventional techniques for improving casting yield are presented. These use a stacked arrangement of castings and riser pressurization to increase the casting yield. Riser pressurization was demonstrated to feed a casting up to four time s the distance of a non-pressurized riser, and can increase casting yield by decreasing the required number of risers. All case studies for this projects were completed and compiled into an SFSA Technical Report that is submitted part of this Final Report

  20. Method of forming a foamed thermoplastic polymer

    DOE Patents [OSTI]

    Duchane, D.V.; Cash, D.L.

    1984-11-21

    A solid thermoplastic polymer is immersed in an immersant solution comprising a compatible carrier solvent and an infusant solution containing an incompatible liquid blowing agent for a time sufficient for the immersant solution to infuse into the polymer. The carrier solvent is then selectively extracted, preferably by a solvent exchange process in which the immersant solution is gradually diluted with and replaced by the infusant solution, so as to selectively leave behind the infustant solution permanently entrapped in the polymer. The polymer is then heated to volatilize the blowing agent and expand the polymer into a foamed state.

  1. Edinburgh College of Art : cast collection and architecture 

    E-Print Network [OSTI]

    Stoica, Ruxandra-Iulia; Stewart, Margaret

    2012-01-01

    The Edinburgh Cast Collection comprises 265 plaster casts of Antique, Renaissance, and Gothic statues, bas reliefs, and architectural passages held at the Edinburgh College of Art and the University of Edinburgh. The plaster casts at the Edinburgh...

  2. Hickey -TT174, casts 21, line 18 to cast 31, line 24 Cruise cast lat(dd.mm.mm) lon(dd.mm.mm) Date/Time (MMDDYYHHMM) Total Scans

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey -TT174, casts 21, line 18 to cast 31, line 24 Cruise cast lat(dd.mm.mm) lon(dd.mm.mm) Date;Hickey -TT174, casts 21, line 18 to cast 31, line 24 Cruise cast lat(dd.mm.mm) lon(dd.mm.mm) Date;Hickey -TT174, casts 21, line 18 to cast 31, line 24 Cruise cast lat(dd.mm.mm) lon(dd.mm.mm) Date

  3. Simulation of Distortion and Residual Stress Development During Heat Treatment of Steel Castings

    SciTech Connect (OSTI)

    Christoph Beckermann; Kent Carlson

    2011-07-22

    Heat treatment and associated processing, such as quenching, are critical during high strength steel casting production. These processes must be managed closely to prevent thermal and residual stresses that may result in distortion, cracking (particularly after machining), re-work, and weld repair. The risk of casting distortion limits aggressive quenching that can be beneficial to the process and yield an improved outcome. As a result of these distortions, adjustments must be made to the casting or pattern design, or tie bars must be added. Straightening castings after heat treatments can be both time-consuming and expensive. Residual stresses may reduce a casting���¢��������s overall service performance, possibly resulting in catastrophic failure. Stress relieving may help, but expends additional energy in the process. Casting software is very limited in predicting distortions during heat treatment, so corrective measures most often involve a tedious trial-and-error procedure. An extensive review of existing heat treatment residual stress and distortion modeling revealed that it is vital to predict the phase transformations and microstructure of the steel along with the thermal stress development during heat treatment. After reviewing the state-of-the-art in heat treatment residual stress and distortion modeling, an existing commercial code was selected because of its advanced capabilities in predicting phase transformations, the evolving microstructure and related properties along with thermal stress development during heat treatment. However, this software was developed for small parts created from forgings or machined stock, and not for steel castings. Therefore, its predictive capabilities for heat treatment of steel castings were investigated. Available experimental steel casting heat treatment data was determined to be of insufficient detail and breadth, and so new heat treatment experiments were designed and performed, casting and heat treating modified versions of the Navy-C ring (a classical test shape for heat treatment experiments) for several carbon and low alloy steels in order to generate data necessary to validate the code. The predicted distortions were in reasonable agreement with the experimentally measured values. However, the final distortions in the castings were small, making it difficult to determine how accurate the predictions truly are. It is recommended that further validation of the software be performed with the aid of additional experiments with large production steel castings that experience significant heat treatment distortions. It is apparent from this research that the mechanical properties of the bonded sand used for cores and sand molds are key in producing accurate stress simulation results. Because of this, experiments were performed to determine the temperature-dependent elastic modulus of a resin-bonded sand commonly utilized in the steel casting industry. The elastic modulus was seen to vary significantly with heating and cooling rates. Also, the retained room temperature elastic modulus after heating was seen to degrade significantly when the sand was heated above 125�������°C. The elastic modulus curves developed in this work can readily be utilized in casting simulation software. Additional experiments with higher heating rates are recommended to determine the behavior of the elastic modulus in the sand close to the mold-metal interface. The commercial heat treatment residual stress and distortion code, once fully validated, is expected to result in an estimated energy savings of 2.15 trillion BTU���¢��������s/year. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology.

  4. ITP Steel: Hydrogen and Nitrogen Control in Ladle and Casting...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    Hydrogen and Nitrogen Control in Ladle and Casting Operations ITP Steel: Hydrogen and Nitrogen Control in Ladle and Casting Operations castingops.pdf More Documents & Publications...

  5. AMD 405: Improved Automotive Suspension Components Cast with...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    AMD 405: Improved Automotive Suspension Components Cast with B206 Alloy AMD 405: Improved Automotive Suspension Components Cast with B206 Alloy 2011 DOE Hydrogen and Fuel Cells...

  6. Mechanical behavior of Nickel base foams for Diesel Particle Filter applications

    E-Print Network [OSTI]

    Paris-Sud XI, Université de

    conditions. 1 Introduction Open-cell Ni foams are mainly used as battery electrodes. The very large spe of microtomography of Ni foams [3], 2D image analysis and electrical resistivity measurements. Creep of alloyed foams creep. A 3D investigation of microtomographic foam images with the Finite Elements Method is finally

  7. Quantum Foam, Gravity and Gravitational Waves

    E-Print Network [OSTI]

    Cahill, R T

    2003-01-01

    The new information-theoretic Process Physics has shown that space is a quantum foam system with gravity being, in effect, an inhomogeneous in-flow of the quantum foam into matter. The theory predicts that absolute motion with respect to this system should be observable, and it is shown here that absolute motion has been detected in at least seven experiments. As well this experimental data also reveals the existence of a gravitational wave phenomena associated with the in-flow. It is shown that Galilean Relativity and Special Relativity are in fact compatible, contrary to current beliefs: absolute motion actually causes the special relativity effects. The new theory of gravity passes all the tests of the previous Newtonian and General Relativity theories, but in addition resolves the numerous gravitational anomalies such as the spiral galaxy `dark matter' effect, the absence of `dark matter' in elliptical galaxies, the inconsistencies in measuring G, the borehole g anomaly, and others. It is shown that Newto...

  8. Materials Applications for Non-Lethal: Aqueous Foams

    SciTech Connect (OSTI)

    GOOLSBY,TOMMY D.; SCOTT,STEVEN H.

    1999-09-15

    High expansion aqueous foam is an aggregation of bubbles that has the appearance of soap suds and is used to isolate individuals both visually and acoustically. It was developed in the 1920's in England to fight coal mine fires and has been widely used since for fire fighting and dust suppression. It was developed at Sandia National Laboratories (SNL) in the 1970's for nuclear safeguards and security applications. In the mid-1990s, the National Institute of Justice (NIJ), the research arm of the Department of Justice, began a project with SNL to determine the applicability of high expansion aqueous foam for correctional applications. NIJ funded the project as part of its search for new and better less-than-lethal weapons for responding to violent and dangerous individuals, where other means of force could lead to serious injuries. The phase one objectives of the project were to select a low-to-no toxicity foam concentrate (foaming agent) with physical characteristics suited for use in a single cell or large prison disturbances, and to determine if the selected foam concentrate could serve as a carrier for Oleoresin Capsicum (OC) irritant. The phase two objectives were to conduct an extensive toxicology review of the selected foam concentrate and OC irritant, and to conduct respiration simulation experiments in the selected high expansion aqueous foam. The phase three objectives were to build a prototype individual cell aqueous foam system and to study the feasibility of aqueous foams for large prison facility disturbances. The phase four and five objectives were to use the prototype system to do large scale foam physical characteristics testing of the selected foam concentrate, and to have the prototype single cell system further evaluated by correctional representatives. Prison rather than street scenarios were evaluated as the first and most likely place for using the aqueous foam since prisons have recurrent incidents where officers and inmates might be seriously injured during violent confrontations. The very low density of the high expansion foam also makes it more suitable for indoor use. This paper summarizes the results of the project.

  9. Part IB Metals Course A: Worked Examples (2022)

    E-Print Network [OSTI]

    Cambridge, University of

    2022-01-01

    and the surface finish is good. A heat­resistant nickel base alloy cast using the lost wax process in which a wax model is surrounded by ceramic, the wax is then burnt off and the metal cast into the ceramic mould

  10. Experimental Investigation of the Effective Foam Viscosity in Unsaturated Porous Media

    SciTech Connect (OSTI)

    Zhang, Z. F.; Zhong, Lirong; White, Mark D.; Szecsody, James E.

    2012-11-01

    Foam has the potential to effectively carry and distribute either aqueous or gaseous amendments to the deep vadose zone for contaminant remediation. However, the transport of foam in porous media is complicated because flow characteristics such as the effective viscosity are affected not only by foam properties but also by the sediment properties and flow conditions. We determined the average effective foam viscosity via a series of laboratory experiments and found that the effective foam viscosity increased with the liquid fraction in foam, the injection rate, and sediment permeability. These impacts are quantified with an empirical expression, which is further demonstrated with data from literature. The results show that the liquid fraction in foam and sediment permeability are two primary factors affecting effective foam viscosity. These results suggest that, when foam is used in deep vadose zone remediation, foam flow will not suffer from gravitational drainage and can distribute amendments uniformly in heterogeneous sediments.

  11. Method and apparatus for improved melt flow during continuous strip casting

    DOE Patents [OSTI]

    Follstaedt, Donald W. (Middletown, OH); King, Edward L. (Trenton, OH); Schneider, Ken C. (Dayton, OH)

    1991-11-12

    The continuous casting of metal strip using the melt overflow process is improved by controlling the weir conditions in the nozzle to provide a more uniform flow of molten metal across the width of the nozzle and reducing the tendency for freezing of metal along the interface with refractory surfaces. A weir design having a sloped rear wall and tapered sidewalls and critical gap controls beneath the weir has resulted in the drastic reduction in edge tearing and a significant improvement in strip uniformity. The floor of the container vessel is preferably sloped and the gap between the nozzle and the rotating substrate is critically controlled. The resulting flow patterns observed with the improved casting process have reduced thermal gradients in the bath, contained surface slag and eliminated undesirable solidification near the discharge area by increasing the flow rates at those points.

  12. Method and apparatus for improved melt flow during continuous strip casting

    DOE Patents [OSTI]

    Follstaedt, D.W.; King, E.L.; Schneider, K.C.

    1991-11-12

    The continuous casting of metal strip using the melt overflow process is improved by controlling the weir conditions in the nozzle to provide a more uniform flow of molten metal across the width of the nozzle and reducing the tendency for freezing of metal along the interface with refractory surfaces. A weir design having a sloped rear wall and tapered sidewalls and critical gap controls beneath the weir has resulted in the drastic reduction in edge tearing and a significant improvement in strip uniformity. The floor of the container vessel is preferably sloped and the gap between the nozzle and the rotating substrate is critically controlled. The resulting flow patterns observed with the improved casting process have reduced thermal gradients in the bath, contained surface slag and eliminated undesirable solidification near the discharge area by increasing the flow rates at those points. 8 figures.

  13. Hickey, W8010A casts 28-31 Hickey, W8010A casts 28-31, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8010A casts 28-31 Hickey, W8010A casts 28-31, page 1 CTD028 #12;Hickey, W8010A casts 28-31 Hickey, W8010A casts 28-31, page 2 CTD028 #12;Hickey, W8010A casts 28-31 Hickey, W8010A casts 28-31, page 3 CTD028 #12;Hickey, W8010A casts 28-31 Hickey, W8010A casts 28-31, page 4 CTD028 #12;Hickey, W8010A

  14. Hickey, W8010A casts 11-20 Hickey, W8010A casts 11-20, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8010A casts 11-20 Hickey, W8010A casts 11-20, page 1 CTD011 #12;Hickey, W8010A casts 11-20 Hickey, W8010A casts 11-20, page 2 CTD011 #12;Hickey, W8010A casts 11-20 Hickey, W8010A casts 11-20, page 3 CTD011 #12;Hickey, W8010A casts 11-20 Hickey, W8010A casts 11-20, page 4 CTD011 #12;Hickey, W8010A

  15. Hickey, W8206_ctd_casts 67-128 Hickey, W8206_ctd_casts 67-128, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8206_ctd_casts 67-128 Hickey, W8206_ctd_casts 67-128, page 1 #12;Hickey, W8206_ctd_casts 67-128 Hickey, W8206_ctd_casts 67-128, page 2 #12;Hickey, W8206_ctd_casts 67-128 Hickey, W8206_ctd_casts 67-128, page 3 #12;Hickey, W8206_ctd_casts 67-128 Hickey, W8206_ctd_casts 67-128, page 4 #12;Hickey

  16. Hickey, W8010A casts 41-51 Hickey, W8010A casts 41-51, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8010A casts 41-51 Hickey, W8010A casts 41-51, page 1 CTD041 #12;Hickey, W8010A casts 41-51 Hickey, W8010A casts 41-51, page 2 CTD041 #12;Hickey, W8010A casts 41-51 Hickey, W8010A casts 41-51, page 3 CTD042 #12;Hickey, W8010A casts 41-51 Hickey, W8010A casts 41-51, page 4 CTD042 #12;Hickey, W8010A

  17. Hickey, W8010A casts 32-34 Hickey, W8010A casts 32-34, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8010A casts 32-34 Hickey, W8010A casts 32-34, page 1 CTD032 #12;Hickey, W8010A casts 32-34 Hickey, W8010A casts 32-34, page 2 CTD032 #12;Hickey, W8010A casts 32-34 Hickey, W8010A casts 32-34, page 3 CTD032 #12;Hickey, W8010A casts 32-34 Hickey, W8010A casts 32-34, page 4 CTD032 #12;Hickey, W8010A

  18. Hickey, W8010A casts 21-27 Hickey, W8010A casts 21-27, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8010A casts 21-27 Hickey, W8010A casts 21-27, page 1 CTD021 #12;Hickey, W8010A casts 21-27 Hickey, W8010A casts 21-27, page 2 CTD021 #12;Hickey, W8010A casts 21-27 Hickey, W8010A casts 21-27, page 3 CTD021 #12;Hickey, W8010A casts 21-27 Hickey, W8010A casts 21-27, page 4 CTD022 #12;Hickey, W8010A

  19. Hickey, W8010A, Casts 7-10 Hickey, W8010A, Casts 7-10, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8010A, Casts 7-10 Hickey, W8010A, Casts 7-10, page 1 CTD007 #12;Hickey, W8010A, Casts 7-10 Hickey, W8010A, Casts 7-10, page 2 CTD007 #12;Hickey, W8010A, Casts 7-10 Hickey, W8010A, Casts 7-10, page 3 CTD007 #12;Hickey, W8010A, Casts 7-10 Hickey, W8010A, Casts 7-10, page 4 CTD007 #12;Hickey, W8010A

  20. Hickey, W8010A casts 35-40 Hickey, W8010A casts 35-40, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8010A casts 35-40 Hickey, W8010A casts 35-40, page 1 CTD035 #12;Hickey, W8010A casts 35-40 Hickey, W8010A casts 35-40, page 2 CTD035 #12;Hickey, W8010A casts 35-40 Hickey, W8010A casts 35-40, page 3 CTD035 #12;Hickey, W8010A casts 35-40 Hickey, W8010A casts 35-40, page 4 CTD035 #12;Hickey, W8010A

  1. Amino resin modified xanthan polymer foamed with a chemical blowing agent

    SciTech Connect (OSTI)

    Hazlett, R.D.; Shu, P.

    1989-05-16

    A method is described for reducing the permeability in an area of a subterranean formation which consists of mixing a gellable composition containing: water, about 0.2 to about 5.0 wt.% of a cross linkable polysaccharide biopolymer having at least one functional group charide biopolymer having at least one functional group selected from a member of the group consisting of an amine, an amide, a hydroxyl, or a thiol group, and about 0.02 to about 5.0 wt.% of an aminoplast resin which reinforces the biopolymer thereby causing the polymer to become more thermally stable. Also included are sufficient transitional metal ions to form a gel of a size and strength sufficient to reduce permeability in a more permeable zone in the formation. A chemical surfactant, and an alkali metal salt of azodicarboxylic acid, are then introduced produce a gas sufficient to foam the composition described above. The composition is then injected into the desired area of the formation where the azodicarboxylic acid decomposes thereby generating nitrogen and carbon dioxide gas in an amount sufficient to form a foam which subsequently hardens and reduces the permeability in the desired area.

  2. Aspiration tests in aqueous foam using a breathing simulator

    SciTech Connect (OSTI)

    Archuleta, M.M.

    1995-12-01

    Non-toxic aqueous foams are being developed by Sandia National Laboratories (SNL) for the National Institute of Justice (NIJ) for use in crowd control, cell extractions, and group disturbances in the criminal justice prison systems. The potential for aspiration of aqueous foam during its use and the resulting adverse effects associated with complete immersion in aqueous foam is of major concern to the NIJ when examining the effectiveness and safety of using this technology as a Less-Than-Lethal weapon. This preliminary study was designed to evaluate the maximum quantity of foam that might be aspirated by an individual following total immersion in an SNL-developed aqueous foam. A.T.W. Reed Breathing simulator equipped with a 622 Silverman cam was used to simulate the aspiration of an ammonium laureth sulfate aqueous foam developed by SNL and generated at expansion ratios in the range of 500:1 to 1000:1. Although the natural instinct of an individual immersed in foam is to cover their nose and mouth with a hand or cloth, thus breaking the bubbles and decreasing the potential for aspiration, this study was performed to examine a worst case scenario where mouth breathing only was examined, and no attempt was made to block foam entry into the breathing port. Two breathing rates were examined: one that simulated a sedentary individual with a mean breathing rate of 6.27 breaths/minute, and one that simulated an agitated or heavily breathing individual with a mean breathing rate of 23.7 breaths/minute. The results of this study indicate that, if breathing in aqueous foam without movement, an air pocket forms around the nose and mouth within one minute of immersion.

  3. Characterization of Technetium Speciation in Cast Stone

    SciTech Connect (OSTI)

    Um, Wooyong; Jung, Hun Bok; Wang, Guohui; Westsik, Joseph H.; Peterson, Reid A.

    2013-11-11

    This report describes the results from laboratory tests performed at Pacific Northwest National Laboratory (PNNL) for the U.S. Department of Energy (DOE) EM-31 Support Program (EMSP) subtask, “Production and Long-Term Performance of Low Temperature Waste Forms” to provide additional information on technetium (Tc) speciation characterization in the Cast Stone waste form. To support the use of Cast Stone as an alternative to vitrification for solidifying low-activity waste (LAW) and as the current baseline waste form for secondary waste streams at the Hanford Site, additional understanding of Tc speciation in Cast Stone is needed to predict the long-term Tc leachability from Cast Stone and to meet the regulatory disposal-facility performance requirements for the Integrated Disposal Facility (IDF). Characterizations of the Tc speciation within the Cast Stone after leaching under various conditions provide insights into how the Tc is retained and released. The data generated by the laboratory tests described in this report provide both empirical and more scientific information to increase our understanding of Tc speciation in Cast Stone and its release mechanism under relevant leaching processes for the purpose of filling data gaps and to support the long-term risk and performance assessments of Cast Stone in the IDF at the Hanford Site.

  4. Sidewall containment of liquid metal with vertical alternating magnetic fields

    DOE Patents [OSTI]

    Lari, Robert J. (Aurora, IL); Praeg, Walter F. (Palos Park, IL); Turner, Larry R. (Naperville, IL); Battles, James E. (Oak Forest, IL); Hull, John R. (Hinsdale, IL); Rote, Donald M. (Lagrange, IL)

    1990-01-01

    An apparatus for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel.

  5. Sidewall containment of liquid metal with vertical alternating magnetic fields

    DOE Patents [OSTI]

    Lari, R.J.; Praeg, W.F.; Turner, L.R.; Battles, J.E.; Hull, J.R.; Rote, D.M.

    1990-12-04

    An apparatus is disclosed for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel. 9 figs.

  6. Sidewall containment of liquid metal with vertical alternating magnetic fields

    DOE Patents [OSTI]

    Lari, R.J.; Praeg, W.F.; Turner, L.R.; Battles, J.E.; Hull, J.R.; Rote, D.M.

    1988-06-17

    An apparatus for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent to the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel. 8 figs.

  7. Molten metal injector system and method

    DOE Patents [OSTI]

    Meyer, Thomas N. (Murrysville, PA); Kinosz, Michael J. (Apollo, PA); Bigler, Nicolas (Morin Heights, CA); Arnaud, Guy (Riviere-Beaudette, CA)

    2003-04-01

    Disclosed is a molten metal injector system including a holder furnace, a casting mold supported above the holder furnace, and a molten metal injector supported from a bottom side of the mold. The holder furnace contains a supply of molten metal having a metal oxide film surface. The bottom side of the mold faces the holder furnace. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The injector projects into the holder furnace and is in fluid communication with the mold cavity. The injector includes a piston positioned within a piston cavity defined by a cylinder for pumping the molten metal upward from the holder furnace and injecting the molten metal into the mold cavity under pressure. The piston and cylinder are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder further includes a molten metal intake for receiving the molten metal into the piston cavity. The molten metal intake is located below the metal oxide film surface of the molten metal when the holder furnace contains the molten metal. A method of injecting molten metal into a mold cavity of a casting mold is also disclosed.

  8. The CAST experiment: status and perspectives

    E-Print Network [OSTI]

    F. J. Iguaz

    2011-10-10

    The status of the solar axion search with the CERN Axion Solar Telescope (CAST) will be discussed. Results from the first part of CAST phase II where the magnet bores were filled with 4He gas at variable pressure in order to scan axion masses up to 0.4 eV will be presented. From the absence of excess X-rays when the magnet was pointing to the Sun, we set a typical upper limit on the axion-photon coupling of g CAST phase II. Expectations for sensibilities will be given. Near future perspectives as well as more long term options for a new helioscope experiment will be evoked.

  9. Use of freeze-casting in advanced burner reactor fuel design

    SciTech Connect (OSTI)

    Lang, A. L.; Yablinsky, C. A.; Allen, T. R. [Dept. of Engineering Physics, Univ. of Wisconsin Madison, 1500 Engineering Drive, Madison, WI 53711 (United States); Burger, J.; Hunger, P. M.; Wegst, U. G. K. [Thayer School of Engineering, Dartmouth College, 8000 Cummings Hall, Hanover, NH 03755 (United States)

    2012-07-01

    This paper will detail the modeling of a fast reactor with fuel pins created using a freeze-casting process. Freeze-casting is a method of creating an inert scaffold within a fuel pin. The scaffold is created using a directional solidification process and results in open porosity for emplacement of fuel, with pores ranging in size from 300 microns to 500 microns in diameter. These pores allow multiple fuel types and enrichments to be loaded into one fuel pin. Also, each pore could be filled with varying amounts of fuel to allow for the specific volume of fission gases created by that fuel type. Currently fast reactors, including advanced burner reactors (ABR's), are not economically feasible due to the high cost of operating the reactors and of reprocessing the fuel. However, if the fuel could be very precisely placed, such as within a freeze-cast scaffold, this could increase fuel performance and result in a valid design with a much lower cost per megawatt. In addition to competitive costs, freeze-cast fuel would also allow for selective breeding or burning of actinides within specific locations in fast reactors. For example, fast flux peak locations could be utilized on a minute scale to target specific actinides for transmutation. Freeze-cast fuel is extremely flexible and has great potential in a variety of applications. This paper performs initial modeling of freeze-cast fuel, with the generic fast reactor parameters for this model based on EBR-II. The core has an assumed power of 62.5 MWt. The neutronics code used was Monte Carlo N-Particle (MCNP5) transport code. Uniform pore sizes were used in increments of 100 microns. Two different freeze-cast scaffold materials were used: ceramic (MgO-ZrO{sub 2}) and steel (SS316L). Separate models were needed for each material because the freeze-cast ceramic and metal scaffolds have different structural characteristics and overall porosities. Basic criticality results were compiled for the various models. Preliminary results show that criticality is achievable with freeze-cast fuel pins despite the significant amount of inert fuel matrix. Freeze casting is a promising method to achieve very precise fuel placement within fuel pins. (authors)

  10. Clamshell Casting Prosenjit Bose, Pat Morin, Michiel Smid, Stefanie Wuhrer

    E-Print Network [OSTI]

    Smid, Michiel

    Clamshell Casting Prosenjit Bose, Pat Morin, Michiel Smid, Stefanie Wuhrer School of Computer}@scs.carleton.ca Abstract A popular manufacturing technique is clamshell casting, where liquid is poured into a cast and the cast is removed by a rotation once the liquid has hardened. We consider the case where the object

  11. Casting with Skewed Ejection Direction Hee-Kap Ahn1

    E-Print Network [OSTI]

    Cheng, Siu-Wing

    Casting with Skewed Ejection Direction Hee-Kap Ahn1 Siu-Wing Cheng2 Otfried Cheong3 Abstract Casting is a manufacturing process in which liquid is poured into a cast (mould) that has a cavity with the shape of the object to be manufactured. The liquid then hardens, after which the cast is removed. We

  12. Deformation during casting of steel: model and material C. Beckermann

    E-Print Network [OSTI]

    Beckermann, Christoph

    Deformation during casting of steel: model and material properties C. Monroe C. Beckermann Dimensional differences between a final casting and its design are casting distortions. Distortion is created by the deformation occurring throughout solidification and further cooling during the casting process. Accurate

  13. COMPARISON OF FATIGUE BEHAVIOR FOR CENTRIFUGALLY CAST AND

    E-Print Network [OSTI]

    Beckermann, Christoph

    COMPARISON OF FATIGUE BEHAVIOR FOR CENTRIFUGALLY CAST AND KEEL BLOCK CAST STEEL J.J. Gradman1 , R The objective of this research was to determine if location through the wall thickness of centrifugal castings affects fatigue properties and to compare fatigue and monotonic tensile properties of centrifugal castings

  14. Modeling of a Foamed Emulsion Bioreactor: II. Model Parametric Sensitivity

    E-Print Network [OSTI]

    Periodicals, Inc. KEYWORDS: VOC control; air pollution control; modeling; biologically activated foam filters are increasingly utilized for air pollution control from stationary sources (Cox and Deshusses in air was examined. Model parametric sensitivity studies showed which parameters affect the removal

  15. Effect of furnace atmosphere on E-glass foaming

    E-Print Network [OSTI]

    Kim, D. S.; Dutton, Bryan C.; Hrma, Pavel R.; Pilon, Laurent

    2006-01-01

    on soda-silicate or soda-lime- silicate melts [2-5,9], or on6]. However, even for soda- lime glasses and metallurgicalon the foaming of soda-lime glass batch in air atmospheres

  16. Carbon foam characterization: sandwich flexure, tensile and shear response 

    E-Print Network [OSTI]

    Sarzynski, Melanie Diane

    2004-09-30

    The focus of this research is characterizing a new material system composed of carbon and graphite foams, which has potential in a wide variety of applications encompassing aerospace, military, offshore, power production ...

  17. Spectroscopic diagnosis of foam z-pinch plasmas on SATURN

    SciTech Connect (OSTI)

    Nash, T.J.; Derzon, M.S.; Allshouse, G.; Deeney, C.; Jobe, D.; Seaman, J.; Gilliland, T.; McGurn, J. [Sandia National Laboratories, Albuquerque, New Mexico 87185-1193 (United States)] [Sandia National Laboratories, Albuquerque, New Mexico 87185-1193 (United States); MacFarlane, J.J.; Wang, P. [University of Wisconsin, Madison, Wisconsin (United States)] [University of Wisconsin, Madison, Wisconsin (United States)

    1997-01-01

    Solid and annular silicon aerogel and agar foams were imploded on the SATURN accelerator to study plasma initiation, acceleration, and stagnation. SATURN delivers 7 MA with a 50 ns rise time to these foam loads. We fielded several spectroscopic diagnostics to measure plasma parameters throughout the z-pinch discharge. A spatially resolved single frame time-gated extreme ultraviolet spectrometer measured the extent of plasma ablation off the surface of the foam. A time integrated crystal spectrometer showed that characteristic K shell radiation of silicon in the aerogel and of sulfur and sodium impurities in the agar were attenuated when the foam loads were coated with a conductive layer of gold. A time-resolved pinhole camera showed that in general the quality of the pinch implosions was poor but improved with increasing efforts to improve current continuity such as prepulse and conductive coatings. {copyright} {ital 1997 American Institute of Physics.}

  18. Spectroscopic diagnosis of foam z-pinch plasmas on SATURN

    SciTech Connect (OSTI)

    Nash, T.J.; Derzon, M.S.; Allshouse, G.; Deeney, C.; Jobe, D.; McGurn, J. [Sandia National Labs., Albuquerque, NM (United States); MacFarlane, J.J.; Wang, P. [Wisconsin Univ., Madison, WI (United States)

    1996-06-01

    Solid and annular silicon aerogel and agar foams were shot on the accelerator SATURN to study plasma initiation, acceleration, and stagnation. SATURN delivers 7 MA with a 50 nsec rise time to these foam loads. We fielded several spectroscopic diagnostics to measure plasma parameters throughout the z-pinch discharge. A spatially resolved single frame time-gated EUV spectrometer measured the extent of plasma ablation off the surface foam. A time integrated crystal spectrometer showed that characteristic K shell radiation of silicon in the aerogel and of S and Na impurities in the agar were all attenuated when the foam loads were coated with a conductive layer of gold. The time resolved pinhole camera showed that in general the quality of the pinch implosions was poor but improved with increasing efforts to improve current continuity such as prepulse and conductive coatings.

  19. Graphite Foams for Lithium-Ion Battery Current Collectors

    SciTech Connect (OSTI)

    Dudney, Nancy J [ORNL; Tiegs, Terry N [ORNL; Kiggans, Jim [ORNL; Jang, Young-Il [ORNL; Klett, James William [ORNL

    2007-01-01

    Graphite open-cell foams, with their very high electronic and thermal conductivities, may serve as high surface area and corrosion resistant current collectors for lithium-ion batteries. As a proof of principle, cathodes were prepared by sintering carbon-coated LiFePO4 particles into the porous graphite foams. Cycling these cathodes in a liquid electrolyte cell showed promising performance even for materials and coatings that have not been optimized. The specific capacity is not limited by the foam structure, but by the cycling performance of the coated LiFePO4 particles. Upon extended cycling for more than 100 deep cycles, no loss of capacity is observed for rates of C/2 or less. The uncoated graphite foams will slowly intercalate lithium reversibly at potentials less than 0.2 volts versus lithium.

  20. Energy Saving Melting and Revert Reduction Technology: Melting Efficiency in Die Casting Operations

    SciTech Connect (OSTI)

    David Schwam

    2012-12-15

    This project addressed multiple aspects of the aluminum melting and handling in die casting operations, with the objective of increasing the energy efficiency while improving the quality of the molten metal. The efficiency of melting has always played an important role in the profitability of aluminum die casting operations. Consequently, die casters need to make careful choices in selecting and operating melting equipment and procedures. The capital cost of new melting equipment with higher efficiency can sometimes be recovered relatively fast when it replaces old melting equipment with lower efficiency. Upgrades designed to improve energy efficiency of existing equipment may be well justified. Energy efficiency is however not the only factor in optimizing melting operations. Melt losses and metal quality are also very important. Selection of melting equipment has to take into consideration the specific conditions at the die casting shop such as availability of floor space, average quantity of metal used as well as the ability to supply more metal during peaks in demand. In all these cases, it is essential to make informed decisions based on the best available data.

  1. Sidewall containment of liquid metal with horizontal alternating magnetic fields

    DOE Patents [OSTI]

    Praeg, W.F.

    1995-01-31

    An apparatus is disclosed for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers. 19 figs.

  2. Roll Casting of Aluminum Alloy Clad Strip

    SciTech Connect (OSTI)

    Nakamura, R.; Tsuge, H. [Graduate School of Osaka Institute of Technology (Japan); Haga, T. [Osaka Institute of Technology, 5-16-1 Omiya Asahiku Osaka city 535-8585 (Japan); Watari, H. [Tokyo Institute of Technology, 4259 Nagatsuda Midoriku Yokohama city 226-8502 (Japan); Kumai, S. [Gunma University, 1-5-1 tenjin cho Kiryu city 376-8515 (Japan)

    2011-01-17

    Casting of aluminum alloy three layers of clad strip was tried using the two sets of twin roll casters, and effects of the casting parameters on the cladding conditions were investigated. One twin roll caster was mounted on the other twin roll caster. Base strip was 8079 aluminum alloy and overlay strips were 6022 aluminum alloy. Effects of roll-load of upper and lower casters and melt temperature of the lower caster were investigated. When the roll-load of the upper and lower caster was large enough, the overlay strip could be solidified and be connected. The overlay strip could be connected when the melt of the overlay strip cast by the lower caster was low enough. Sound three layers of clad strip could be cast by proper conditions.

  3. H-Series Cast Austenitic Stainless Steels

    Broader source: Energy.gov [DOE]

    Cast H-Series austenitic steels are used extensively in several industries for a broad range of high-temperature applications. The H-Series stainless steels have evolved over many years of complex...

  4. Process for producing carbon foams for energy storage devices

    DOE Patents [OSTI]

    Kaschmitter, James L. (Pleasanton, CA); Mayer, Steven T. (San Leandro, CA); Pekala, Richard W. (Pleasant Hill, CA)

    1998-01-01

    A high energy density capacitor incorporating a variety of carbon foam electrodes is described. The foams, derived from the pyrolysis of resorcinol-formaldehyde and related polymers, are high density (0.1 g/cc-1.0 g/cc) electrically conductive and have high surface areas (400 m.sup.2 /g-1000 m.sup.2 /g). Capacitances on the order of several tens of farad per gram of electrode are achieved.

  5. Process for producing carbon foams for energy storage devices

    DOE Patents [OSTI]

    Kaschmitter, J.L.; Mayer, S.T.; Pekala, R.W.

    1998-08-04

    A high energy density capacitor incorporating a variety of carbon foam electrodes is described. The foams, derived from the pyrolysis of resorcinol-formaldehyde and related polymers, are high density (0.1 g/cc--1.0 g/cc) electrically conductive and have high surface areas (400 m{sup 2}/g--1,000 m{sup 2}/g). Capacitances on the order of several tens of farad per gram of electrode are achieved. 9 figs.

  6. Plackett-Burman Analysis of Glass Microballoon Filled Syntactic Foams

    SciTech Connect (OSTI)

    Keller, Jennie [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Smith, Zachary [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Bello, Mollie [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Cordes, Nikolaus Lynn [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2014-08-21

    Syntactic foams are an important category of composite materials that have abundant applications in a wide variety of fields. The current study utilized a Plackett-Burman (PB) experimental design to investigate the main effects of six variables on properties of syntactic foams formulated from a silicone elastomer and glass microballoons(MB). Findings from this investigation are meant to identify the most significant variables with respect to foam properties. Eight foam samples were created and tested using thermal, physical and mechanical techniques. The data from these tests was then evaluated using a Plackett-Burman response coefficient calculation (RCC). This calculation was applied to determine the statistical significance of the selected variables by comparison with a dummy variable. The data suggests that thermal properties, such as glass transition temperature and coefficient of thermal expansion, do not rely on any of the studied variables. Physical and mechanical measurements however were found to depend heavily on the matrix composition and the vacuum pressure used during mixing. Some variables were found to have little to no effect on any of the studied properties. Ultimately, this data could be used to formulate a comprehensive catalogue of syntactic foams based on their compositions. This type of database would allow customers in industry to identify which syntactic foam would best fit their application according to one or two properties.

  7. Low Background Micromegas in CAST

    E-Print Network [OSTI]

    Garza, J G; Calvet, D; Castel, J F; Christensen, F E; Dafni, T; Davenport, M; Decker, T; Ferrer-Ribas, E; Galán, J; García, J A; Giomataris, I; Hill, R M; Iguaz, F J; Irastorza, I G; Jakobsen, A C; Jourde, D; Mirallas, H; Ortega, I; Papaevangelou, T; Pivovaroff, M J; Ruz, J; Tomás, A; Vafeiadis, T; Vogel, J K

    2015-01-01

    Solar axions could be converted into x-rays inside the strong magnetic field of an axion helioscope, triggering the detection of this elusive particle. Low background x-ray detectors are an essential component for the sensitivity of these searches. We report on the latest developments of the Micromegas detectors for the CERN Axion Solar Telescope (CAST), including technological pathfinder activities for the future International Axion Observatory (IAXO). The use of low background techniques and the application of discrimination algorithms based on the high granularity of the readout have led to background levels below 10$^{-6}$ counts/keV/cm$^2$/s, more than a factor 100 lower than the first generation of Micromegas detectors. The best levels achieved at the Canfranc Underground Laboratory (LSC) are as low as 10$^{-7}$ counts/keV/cm$^2$/s, showing good prospects for the application of this technology in IAXO. The current background model, based on underground and surface measurements, is presented, as well as ...

  8. Low Background Micromegas in CAST

    E-Print Network [OSTI]

    J. G. Garza; S. Aune; D. Calvet; J. F. Castel; F. E. Christensen; T. Dafni; M. Davenport; T. Decker; E. Ferrer-Ribas; J. Galán; J. A. García; I. Giomataris; R. M. Hill; F. J. Iguaz; I. G. Irastorza; A. C. Jakobsen; D. Jourde; H. Mirallas; I. Ortega; T. Papaevangelou; M. J. Pivovaroff; J. Ruz; A. Tomás; T. Vafeiadis; J. K. Vogel

    2015-03-17

    Solar axions could be converted into x-rays inside the strong magnetic field of an axion helioscope, triggering the detection of this elusive particle. Low background x-ray detectors are an essential component for the sensitivity of these searches. We report on the latest developments of the Micromegas detectors for the CERN Axion Solar Telescope (CAST), including technological pathfinder activities for the future International Axion Observatory (IAXO). The use of low background techniques and the application of discrimination algorithms based on the high granularity of the readout have led to background levels below 10$^{-6}$ counts/keV/cm$^2$/s, more than a factor 100 lower than the first generation of Micromegas detectors. The best levels achieved at the Canfranc Underground Laboratory (LSC) are as low as 10$^{-7}$ counts/keV/cm$^2$/s, showing good prospects for the application of this technology in IAXO. The current background model, based on underground and surface measurements, is presented, as well as the strategies to further reduce the background level. Finally, we will describe the R&D paths to achieve sub-keV energy thresholds, which could broaden the physics case of axion helioscopes.

  9. Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking

    SciTech Connect (OSTI)

    Das, S.K.; Ningileri, S.; Long, Z.; Saito, K.; Khraisheh, M.; Hassan, M.H.; Kuwana, K.; Han, Q.; Viswanathan, S.; Sabau, A.S.; Clark, J.; Hyrn, J. (ANL)

    2006-08-15

    Approximately 68% of the aluminum produced in the United States is first cast into ingots prior to further processing into sheet, plate, extrusions, or foil. The direct chill (DC) semi-continuous casting process has been the mainstay of the aluminum industry for the production of ingots due largely to its robust nature and relative simplicity. Though the basic process of DC casting is in principle straightforward, the interaction of process parameters with heat extraction, microstructural evolution, and development of solidification stresses is too complex to analyze by intuition or practical experience. One issue in DC casting is the formation of stress cracks [1-15]. In particular, the move toward larger ingot cross-sections, the use of higher casting speeds, and an ever-increasing array of mold technologies have increased industry efficiencies but have made it more difficult to predict the occurrence of stress crack defects. The Aluminum Industry Technology Roadmap [16] has recognized the challenges inherent in the DC casting process and the control of stress cracks and selected the development of 'fundamental information on solidification of alloys to predict microstructure, surface properties, and stresses and strains' as a high-priority research need, and the 'lack of understanding of mechanisms of cracking as a function of alloy' and 'insufficient understanding of the aluminum solidification process', which is 'difficult to model', as technology barriers in aluminum casting processes. The goal of this Aluminum Industry of the Future (IOF) project was to assist the aluminum industry in reducing the incidence of stress cracks from the current level of 5% to 2%. Decreasing stress crack incidence is important for improving product quality and consistency as well as for saving resources and energy, since considerable amounts of cast metal could be saved by eliminating ingot cracking, by reducing the scalping thickness of the ingot before rolling, and by eliminating butt sawing. Full-scale industrial implementation of the results of the proposed research would lead to energy savings in excess of 6 trillion Btu by the year 2020. The research undertaken in this project aimed to achieve this objective by a collaboration of industry, university, and national laboratory personnel through Secat, Inc., a consortium of aluminum companies. During the four-year project, the industrial partners and the research team met in 16 quarterly meetings to discuss research results and research direction. The industrial partners provided guidance, facilities, and experience to the research team. The research team went to two industrial plants to measure temperature distributions in commercial 60,000-lb DC casting ingot production. The project focused on the development of a fundamental understanding of ingot cracking and detailed models of thermal conditions, solidification, microstructural evolution, and stress development during the initial transient in DC castings of the aluminum alloys 3004 and 5182. The microstructure of the DC casting ingots was systematically characterized. Carefully designed experiments were carried out at the national laboratory and university facilities as well as at the industrial locations using the industrial production facilities. The advanced computational capabilities of the national laboratories were used for thermodynamic and kinetic simulations of phase transformation, heat transfer and fluid flow, solidification, and stress-strain evolution during DC casting. The achievements of the project are the following: (1) Identified the nature of crack formation during DC casting; (2) Developed a novel method for determining the mechanical properties of an alloy at the nonequilibrium mushy zone of the alloy; (3) Measured heat transfer coefficients (HTCs) between the solidifying ingot and the cooling water jet; (4) Determined the material constitutive model at high temperatures; and (5) Developed computational capabilities for the simulation of cracking formation in DC casting ingot. The models and the database de

  10. Reflectance Map Techniques for Analyzing Surface Defects in Metal Castings

    E-Print Network [OSTI]

    Woodham, Robert J.

    1978-06-01

    This report explores the relation between image intensity and object shape. It is shown that image intensity is related to surface orientation and that a variation in image intensity is related to surface curvature. ...

  11. Reliability Tools for Resonance Inspection of Light Metal Castings |

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    AFDC Printable Version Share this resource Send a link to EERE: Alternative Fuels Data Center Home Page to someone by E-mail Share EERE: Alternative Fuels Data Center Home Page on Facebook Tweet about EERE: Alternative Fuels Data Center Home Page on Twitter Bookmark EERE: Alternative Fuels Data Center Home Page on Google Bookmark EERE: Alternative Fuels Data Center Home Page on Delicious RankADVANCED MANUFACTURINGEnergy BillsNo. 195 - Oct. 7,DOERTIRegulatory and Financial

  12. ITP Metal Casting: Corrosion Testing Practices - High Alloy Corrosion

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    AFDC Printable Version Share this resource Send a link to EERE: Alternative Fuels Data Center Home Page to someone by E-mail Share EERE: Alternative Fuels Data Center Home Page on Facebook Tweet about EERE: Alternative Fuels Data Center Home Page on Twitter Bookmark EERE: Alternative Fuels Data Center Home Page on Google Bookmark EERE: Alternative Fuels Data Center Home Page on Delicious Rank EERE:FinancingPetroleum12,ExecutiveFinancingR Walls21,Equipment: EnergyStandardsITCBoilers

  13. Enhanced Resonance Inspection for Light Metal Castings | Department of

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    AFDC Printable Version Share this resource Send a link to EERE: Alternative Fuels Data Center Home Page to someone by E-mail Share EERE: Alternative Fuels Data Center Home Page on Facebook Tweet about EERE: Alternative Fuels Data Center Home Page on Twitter Bookmark EERE: Alternative Fuels Data Center Home Page on Google Bookmark EERE: Alternative Fuels Data Center Home Page on Delicious Rank EERE:FinancingPetroleum12, 2015 Infographiclighbulbs - high-resolution2

  14. Methods and apparatus for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    DOE Patents [OSTI]

    Stoddard, Nathan G

    2014-01-14

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

  15. Methods and apparatuses for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    DOE Patents [OSTI]

    Stoddard, Nathan G. (Gettysburg, PA)

    2011-11-01

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

  16. Journal of Ceramic Processing Research. Vol. 12, No. 6, pp. 691~694 (2011) J O U R N A L O F

    E-Print Network [OSTI]

    Volinsky, Alex A.

    2011-01-01

    Journal of Ceramic Processing Research. Vol. 12, No. 6, pp. 691~694 (2011) 691 J O U R N A L O F Ceramic Processing Research Microstructure and quality of SiC foam filters for casting Fengzhang Rena quality indicator of ceramic foam filters used in metal casting. Maximum compressive strain at high

  17. Casting out nines is a method for checking the accuracy of arithmetic ...

    E-Print Network [OSTI]

    Roames, Renee S

    2015-08-19

    Math 13700. Casting out Nines. Assignment #34. Casting out nines is a method for checking the accuracy of arithmetic. You can cast out nines by adding the ...

  18. The CAST Manual John Yen*, Thomas R. Ioerger^, Michael S. Miller^, Shuang Sun*,

    E-Print Network [OSTI]

    The CAST Manual John Yen*, Thomas R. Ioerger^, Michael S. Miller^, Shuang Sun*, Kaivan Kamali................................................................................................................. 4 3. About CAST ........................................................................................................... 6 3.3. CAST architecture

  19. Predicting Pattern Tooling and Casting Dimensions for Investment Casting - Phase II

    SciTech Connect (OSTI)

    Sabau, Adrian S [ORNL

    2005-09-01

    The investment casting process allows the production of complex-shape parts and close dimensional tolerances. One of the most important phases in the investment casting process is the design of the pattern die. Pattern dies are used to create wax patterns by injecting wax into dies. The wax patterns are used to create a ceramic shell by the application of a series of ceramic coatings, and the alloy is cast into the dewaxed shell mold (Fig. 1.1). However, the complexity of shape and the close dimensional tolerances required in the final casting make it difficult to determine tooling dimensions. The final linear dimension of the casting depends on the cumulative effects of the linear expansions or contractions in each step of the investment casting process (Fig. 1.2). In most cases, the mold geometry or cores restrict the shrinkage of the pattern or the cast part, and the final casting dimensions may be affected by time-dependent processes such as viscoelastic deformation of the wax, and viscoplastic creep and plastic deformations of the shell and alloy. The pattern die is often reworked several times to produce castings whose dimensions are within acceptable tolerances. To date, investment casting technology has been based on hands-on training and experience. Technical literature is limited to experimental, phenomenological studies aimed at obtaining empirical correlations for quick and easy application in industry. The goal of this project was to predict casting dimensions for investment castings in order to meet blueprint nominal during the first casting run. Several interactions have to be considered in a coupled manner to determine the shrinkage factors: these are the die-wax, wax-shell, and shell-alloy interactions (as illustrated in Fig. 1.3). In this work, the deformations of the die-wax and shell-alloy systems were considered in a coupled manner, while the coupled deformation of the wax-shell system was not considered. Future work is needed in order to deliver to industry a computer program in which all three systems are coupled for determining the dimensions of the wax pattern, the shell mold, and casting in a sequential but coupled manner.

  20. Separate effects identification via casting process modeling for experimental measurement of U–Pu–Zr alloys

    SciTech Connect (OSTI)

    J. Crapps; D. S. DeCroix; J. D. Galloway; D. A. Korzekwa; R. Aikin; R. Fielding; R. Kennedy; C. Unal

    2013-11-01

    Computational simulations of gravity casting processes for metallic U–Pu–Zr nuclear fuel rods have been performed using a design-of-experiments technique to determine the fluid flow, liquid heat transfer, and solid heat transfer parameters which most strongly influence the process solidification speed and fuel rod porosity. The results are used to make recommendations for the best investment of experimental time and effort to measure process parameters.

  1. Bubbling supertubes and foaming black holes

    SciTech Connect (OSTI)

    Bena, Iosif; Warner, Nicholas P.

    2006-09-15

    We construct smooth BPS three-charge geometries that resolve the zero-entropy singularity of the U(1)xU(1) invariant black ring. This singularity is resolved by a geometric transition that results in geometries without any branes sources or singularities but with nontrivial topology. These geometries are both ground states of the black ring, and nontrivial microstates of the D1-D5-P system. We also find the form of the geometries that result from the geometric transition of N zero-entropy black rings, and argue that, in general, such geometries give a very large number of smooth bound-state three-charge solutions, parametrized by 6N functions. The generic microstate solution is specified by a four-dimensional hyper-Kaehler geometry of a certain signature, and contains a 'foam' of nontrivial two-spheres. We conjecture that these geometries will account for a significant part of the entropy of the D1-D5-P black hole, and that Mathur's conjecture might reduce to counting certain hyper-Kaehler manifolds.

  2. The X-ray Telescope of CAST

    E-Print Network [OSTI]

    M. Kuster; H. Bräuninger; S. Cébrian; M. Davenport; C. Elefteriadis; J. Englhauser; H. Fischer; J. Franz; P. Friedrich; R. Hartmann; F. H. Heinsius; D. H. H. Hoffmann; G. Hoffmeister; J. N. Joux; D. Kang; K. Königsmann; R. Kotthaus; T. Papaevangelou; C. Lasseur; A. Lippitsch; G. Lutz; J. Morales; A. Rodríguez; L. Strüder; J. Vogel; K. Zioutas

    2007-05-10

    The Cern Axion Solar Telescope (CAST) is in operation and taking data since 2003. The main objective of the CAST experiment is to search for a hypothetical pseudoscalar boson, the axion, which might be produced in the core of the sun. The basic physics process CAST is based on is the time inverted Primakoff effect, by which an axion can be converted into a detectable photon in an external electromagnetic field. The resulting X-ray photons are expected to be thermally distributed between 1 and 7 keV. The most sensitive detector system of CAST is a pn-CCD detector combined with a Wolter I type X-ray mirror system. With the X-ray telescope of CAST a background reduction of more than 2 orders off magnitude is achieved, such that for the first time the axion photon coupling constant g_agg can be probed beyond the best astrophysical constraints g_agg < 1 x 10^-10 GeV^-1.

  3. Bright x-ray sources from laser irradiation of foams with high...

    Office of Scientific and Technical Information (OSTI)

    Bright x-ray sources from laser irradiation of foams with high concentration of Ti Citation Details In-Document Search Title: Bright x-ray sources from laser irradiation of foams...

  4. Effect of microstructure of closed cell foam on strength and effective stiffness 

    E-Print Network [OSTI]

    Sue, Ji Woong

    2007-04-25

    This research is concerned with the modeling and failure analysis of closed cell foam with various scales of microstructure that is disordered due to defects. This foam material is used for the forward bipod closeout on ...

  5. Mesoscale simulation of shocked poly-(4-methyl-1-pentene) (PMP) foams.

    SciTech Connect (OSTI)

    Schroen, Diana Grace; Flicker, Dawn G.; Haill, Thomas A.; Root, Seth; Mattsson, Thomas Kjell Rene

    2011-06-01

    Hydrocarbon foams are commonly used in HEDP experiments, and are subject to shock compression from tens to hundreds of GPa. Modeling foams is challenging due to the heterogeneous character of the foam. A quantitative understanding of foams under strong dynamic compression is sought. We use Sandia's ALEGRA-MHD code to simulate 3D mesoscale models of pure poly(4-methyl-1-petene) (PMP) foams. We employ two models of the initial polymer-void structure of the foam and analyze the statistical properties of the initial and shocked states. We compare the simulations to multi-Mbar shock experiments at various initial foam densities and flyer impact velocities. Scatter in the experimental data may be a consequence of the initial foam inhomogeneity. We compare the statistical properties the simulations with the scatter in the experimental data.

  6. The Effect of Moisture Absorption on the Physical Properties of Polyurethane Shape Memory Polymer Foams 

    E-Print Network [OSTI]

    Yu, Ya-Jen

    2012-07-16

    The effect of moisture absorption on the glass transition temperature (Tg) and stress/strain behavior of network polyurethane shape memory polymer (SMP) foams has been investigated. With our ultimate goal of engineering polyurethane SMP foams...

  7. Analysis of a graphite foam-NaCl latent heat storage system for...

    Broader source: All U.S. Department of Energy (DOE) Office Webpages (Extended Search)

    Analysis of a graphite foam-NaCl latent heat storage system for supercritical CO2 power cycles for concentrated solar power Title Analysis of a graphite foam-NaCl latent heat...

  8. Plackett-Burman experimental design to facilitate syntactic foam development

    DOE Public Access Gateway for Energy & Science Beta (PAGES Beta)

    Smith, Zachary D.; Keller, Jennie R.; Bello, Mollie; Cordes, Nikolaus L.; Welch, Cynthia F.; Torres, Joseph A.; Goodwin, Lynne A.; Pacheco, Robin M.; Sandoval, Cynthia W.

    2015-09-14

    The use of an eight-experiment Plackett–Burman method can assess six experimental variables and eight responses in a polysiloxane-glass microsphere syntactic foam. The approach aims to decrease the time required to develop a tunable polymer composite by identifying a reduced set of variables and responses suitable for future predictive modeling. The statistical design assesses the main effects of mixing process parameters, polymer matrix composition, microsphere density and volume loading, and the blending of two grades of microspheres, using a dummy factor in statistical calculations. Responses cover rheological, physical, thermal, and mechanical properties. The cure accelerator content of the polymer matrix andmore »the volume loading of the microspheres have the largest effects on foam properties. These factors are the most suitable for controlling the gel point of the curing foam, and the density of the cured foam. The mixing parameters introduce widespread variability and therefore should be fixed at effective levels during follow-up testing. Some responses may require greater contrast in microsphere-related factors. As a result, compared to other possible statistical approaches, the run economy of the Plackett–Burman method makes it a valuable tool for rapidly characterizing new foams.« less

  9. Vacuum Furnace Brazing Open Cell Reticulated Foam to Stainless Steel Tubing

    SciTech Connect (OSTI)

    Korinko, P.S.

    2002-09-13

    This paper describes the intended application and development effort required to braze the copper foam to the stainless steel tubing.

  10. The Stokes experiment in a foam S.J. Cox, M.D. Alonso

    E-Print Network [OSTI]

    Cox, Simon

    dishwasher detergent (Fairy Liquid) and push gas through a sparger immersed in the solution. The foam which

  11. The CAST experiment: status and perspectives

    E-Print Network [OSTI]

    Esther Ferrer Ribas; for the CAST Collaboration

    2009-12-21

    The status of the solar axion search with the CERN Axion Solar Telescope (CAST) will be discussed. Results from the first part of CAST phase II where the magnet bores were filled with \\hefour gas at variable pressure in order to scan \\ma up to 0.4 eV will be presented. From the absence of excess X-rays when the magnet was pointing to the Sun, we set a typical upper limit on the axion-photon coupling of $\\gag \\lesssim 2.17 \\times10^{-10}$GeV$^{-1}$ at 95% CL for \\ma$CAST phase II. Expectations for sensibilities will be given. Near future perspectives as well as more long term options for a new helioscope experiment will be evoked.

  12. Compound cast product and method for producing a compound cast product

    DOE Patents [OSTI]

    Meyer, Thomas N. (3987 Murray Highlands Cir., Murrysville, PA 15668-1747); Viswanathan, Srinath (1104 Albermarle La., Knoxville, TN 37923)

    2002-09-17

    A compound cast product is formed in a casting mold (14) having a mold cavity (16) sized and shaped to form the cast product. A plurality of injectors (24) is supported from a bottom side (26) of the casting mold (14). The injectors (24) are in fluid communication with the mold cavity (16) through the bottom side (26) of the casting mold (14). A molten material holder furnace (12) is located beneath the casting mold (14). The holder furnace (12) defines molten material receiving chambers (36) configured to separately contain supplies of two different molten materials (37, 38). The holder furnace (12) is positioned such that the injectors (24) extend downward into the receiving chamber (36). The receiving chamber (36) is separated into at least two different flow circuits (51, 52). A first molten material (37) is received in a first flow circuit (51), and a second molten material (38) is received into a second flow circuit (52). The first and second molten materials (37, 38) are injected into the mold cavity (16) by the injectors (24) acting against the force of gravity. The injectors (24) are positioned such that the first and second molten materials (37, 38) are injected into different areas of the mold cavity (16). The molten materials (37, 38) are allowed to solidify and the resulting compound cast product is removed from the mold cavity (16).

  13. Modeling of a Foamed Emulsion Bioreactor: I. Model Development and Experimental Validation

    E-Print Network [OSTI]

    , a new type of bioreactor for air pollution control referred to as the foamed emulsion bior- eactor (FEBR of an actively growing culture of pollutant-degrading microor- ganisms, made into a foam with the air undergoing. KEYWORDS: VOC control; air pollution control; modeling; biologically activated foam; biodegradation

  14. Flow transitions in two-dimensional foams Christopher Gilbreth, Scott Sullivan, and Michael Dennin

    E-Print Network [OSTI]

    Dennin, Michael

    Flow transitions in two-dimensional foams Christopher Gilbreth, Scott Sullivan, and Michael Dennin: November 21, 2006) For sufficiently slow rates of strain, flowing foam can exhibit inhomogeneous flows. The nature of these flows is an area of active study in both two-dimensional model foams and three

  15. Foam Control using a Fluidized Bed of Hydrophobic Particles by Clara Mata*

    E-Print Network [OSTI]

    Joseph, Daniel D.

    Foam Control using a Fluidized Bed of Hydrophobic Particles by Clara Mata* & D. D. Joseph may be strongly suppressed by fluidizing hydrophilic particles in the bubbly mixture below the foam different tests (particle-induced film rupture and foam shake test), but they did not use a fluidized bed

  16. Glass foams: formation, transport properties, and heat, mass, and radiation transfer

    E-Print Network [OSTI]

    Pilon, Laurent

    Glass foams: formation, transport properties, and heat, mass, and radiation transfer Andrei G models for thermophysical and transport properties and heat, mass, and radiation transfer in glass foams. In addition, the new results on simulation of combined conduction and radiation heat transfer in glass foams

  17. Ultra-low density microcellular polymer foam and method

    DOE Patents [OSTI]

    Simandl, R.F.; Brown, J.D.

    1996-03-19

    An ultra-low density, microcellular open-celled polymer foam and a method for making such foam are disclosed. A polymer is dissolved in a heated solution consisting essentially of at least one solvent for the dissolution of the polymer in the heated solution and the phase inversion of the dissolved polymer to a liquid gel upon sufficient cooling of the heated solution. The heated solution is contained in a containment means provided with a nucleating promoting means having a relatively rough surface formed of fixed nucleating sites. The heated solution is cooled for a period of time sufficient to form a liquid gel of the polymer by phase inversion. From the gel, a porous foam having a density of less than about 12.0 mg/cm{sup 3} and open porosity provided by well interconnected strut morphology is formed.

  18. Ultra-low density microcellular polymer foam and method

    DOE Patents [OSTI]

    Simandl, Ronald F. (Farragut, TN); Brown, John D. (Harriman, TN)

    1996-01-01

    An ultra-low density, microcellular open-celled polymer foam and a method for making such foam. A polymer is dissolved in a heated solution consisting essentially of at least one solvent for the dissolution of the polymer in the heated solution and the phase inversion of the dissolved polymer to a liquid gel upon sufficient cooling of the heated solution. The heated solution is contained in a containment means provided with a nucleating promoting means having a relatively rough surface formed of fixed nucleating sites. The heated solution is cooled for a period of time sufficient to form a liquid gel of the polymer by phase inversion. From the gel, a porous foam having a density of less than about 12.0 mg/cm.sup.3 and open porosity provided by well interconnected strut morphology is formed.

  19. Search for solar chameleons and relic axions with CAST

    E-Print Network [OSTI]

    Cantatore, G; Zioutas, K

    2015-01-01

    New CAST research proposal covering the period 2015-2018 detailing motivations and novel techniques to search for solar Chameleons and new searches for relic Axions with the CAST dipole magnet

  20. Method for providing a low density high strength polyurethane foam

    DOE Patents [OSTI]

    Whinnery, Jr., Leroy L.; Goods, Steven H.; Skala, Dawn M.; Henderson, Craig C.; Keifer, Patrick N.

    2013-06-18

    Disclosed is a method for making a polyurethane closed-cell foam material exhibiting a bulk density below 4 lbs/ft.sup.3 and high strength. The present embodiment uses the reaction product of a modified MDI and a sucrose/glycerine based polyether polyol resin wherein a small measured quantity of the polyol resin is "pre-reacted" with a larger quantity of the isocyanate in a defined ratio such that when the necessary remaining quantity of the polyol resin is added to the "pre-reacted" resin together with a tertiary amine catalyst and water as a blowing agent, the polymerization proceeds slowly enough to provide a stable foam body.

  1. APPROXIMATION OF A TWOPHASE CONTINUOUS CASTING STEFAN PROBLEM

    E-Print Network [OSTI]

    APPROXIMATION OF A TWO­PHASE CONTINUOUS CASTING STEFAN PROBLEM Zhiming Chen \\Lambda Lishang Jiang y Abstract. The continuous casting Stefan problem is a mathematical model describing the solidification with convection of a material being cast continuously with a prescribed velocity. We propose a practical piecewise

  2. Beam casting implicit surfaces on the GPU with interval arithmetic

    E-Print Network [OSTI]

    de Figueiredo, Luiz Henrique

    Beam casting implicit surfaces on the GPU with interval arithmetic Francisco Ganacim, Luiz Henrique, Brazil Abstract--We present a GPU-based beam-casting method for rendering implicit surfaces in real time. INTRODUCTION Rendering surfaces with ray casting is perhaps the clearest example of a potentially

  3. Simultaneous Cast Shadows, Illumination and Geometry Inference Using Hypergraphs

    E-Print Network [OSTI]

    Samaras, Dimitris

    Simultaneous Cast Shadows, Illumination and Geometry Inference Using Hypergraphs Alexandros Abstract--The cast shadows in an image provide important information about illumination and geometry environment, a set of geometry parameters, and an estimate of the cast shadows in the scene given a single

  4. CAST STRATEGIC PLAN 2011-2014 Student Success

    E-Print Network [OSTI]

    Salvaggio, Carl

    CAST STRATEGIC PLAN 2011-2014 Student Success Academic Affairs Objectives Support the initiative to require advising in the first year. CAST Objectives Outcome Measurements Lead Person(s) Target 1a). Meet/exceed the current 1st- and 2nd-year retention rate for our college CAST 1st- and 2nd-year retention rates (done

  5. Converge-Cast with MIMO , Xinbing Wang3

    E-Print Network [OSTI]

    Wang, Xinbing

    Converge-Cast with MIMO Luoyi Fu1 , Yi Qin2 , Xinbing Wang3 , Xue Liu4 1,2,3 Depart. of Electronic, called converge-cast, where each of the n nodes in the network act as a destination with k ran- domly two many-to-one cooperative schemes under converge-cast for both static and mobile ad hoc networks

  6. Modelling of reoxidation inclusion formation in steel sand casting

    E-Print Network [OSTI]

    Beckermann, Christoph

    Modelling of reoxidation inclusion formation in steel sand casting A. J. Melendez, K. D. Carlson pouring, as well as their final locations on the surface of steel sand castings. Inclusions originate. The inclusion model is implemented in a general-purpose casting simulation code. The model is validated

  7. Morphological castes in a vertebrate M. J. O'Riain*

    E-Print Network [OSTI]

    Danchin, Etienne

    Morphological castes in a vertebrate M. J. O'Riain* , J. U. M. Jarvis , R. Alexander§ , R of reproduction in females. This is the only known example of morphological castes in a vertebrate and is distinct breeding vertebrates. The evolution of castes in a mammal and insects represents a striking example

  8. Macei Alagoas -Brazil Beam casting implicit surfaces on the GPU

    E-Print Network [OSTI]

    de Figueiredo, Luiz Henrique

    Maceió ­ Alagoas - Brazil Beam casting implicit surfaces on the GPU with interval arithmetic Francisco Ganacim Luiz Henrique de Figueiredo Diego Nehab #12;8/27/11 2Beam casting implicit surfaces on the GPU with interval arithmetic 2 Barth: Related work Introduction #12;8/27/11 3Beam casting implicit

  9. Genetic Evidence on the Origins of Indian Caste Populations

    E-Print Network [OSTI]

    Bamshad, Michael; Kivisild, Toomas; Watkins, W. Scott; Dixon, Mary E.; Ricker, Chris E.; Rao, Baskara B.; Naidu, J. Mastan; Prasad, B. V. Ravi; Reddy, P. Govinda; Rasanayagam, Arani; Papiha, Surinder S.; Villems, Richard; Redd, Alan J.; Hammer, Michael F.; Nguyen, Son V.; Carroll, Marion L.; Batzer, Mark A.; Jorde, Lynn B.

    2001-11-01

    have established the Hindu caste system and placed themselves primarily in castes of higher rank. To explore the impact of West Eurasians on contemporary Indian caste populations, we compared mtDNA (400 bp of hypervariable region 1 and 14 restriction...

  10. Application of New Feeding Rules To Risering of Steel Castings

    E-Print Network [OSTI]

    Beckermann, Christoph

    and predicted shrinkage porosity in the castings to the expected level of porosity based on the new feeding1 Application of New Feeding Rules To Risering of Steel Castings Doug Smith , Tony Faivre , Shouzhu Engineering , ABC-NACO TECHNOLOGIES, Lombard, IL1 Project Engineer - Casting Simulation, ABC-NACO TECHNOLOGIES

  11. MODELING OF POROSITY FORMATION AND FEEDING FLOW IN STEEL CASTING

    E-Print Network [OSTI]

    Beckermann, Christoph

    , or even larger shrinkage cavities found in inadequately fed cast sections. Microporosity can cause leaksMODELING OF POROSITY FORMATION AND FEEDING FLOW IN STEEL CASTING Kent D. Carlson, Zhiping Lin pressure, feeding flow, and porosity formation and growth in steel castings during solidification

  12. Effect of Shrinkage on Service Performance of Steel Castings

    E-Print Network [OSTI]

    Beckermann, Christoph

    Effect of Shrinkage on Service Performance of Steel Castings Richard Hardin and Christoph are summarized. Hardin, R., and Beckermann, C., "Effect of Shrinkage on Service Performance of Steel Castings An overview of the objectives and progress made by the "Integrated Design of Steel Castings for Service

  13. Feeding and Risering of High Alloy Steel Castings

    E-Print Network [OSTI]

    Beckermann, Christoph

    Feeding and Risering of High Alloy Steel Castings Kent D. Carlson, Shouzhu Ou and Christoph radiographically sound castings at 2 pct sensitivity. By comparing results between plate casting trials known as the Niyama criterion and ASTM shrinkage x-ray level. This relationship was then used

  14. Clean Cast Steel Technology - Machinability and Technology Transfer

    SciTech Connect (OSTI)

    C. E. Bates; J. A. Griffin

    2000-05-01

    There were two main tasks in the Clean Cast Steel Technology - Machinability and Technology Transfer Project. These were (1) determine the processing facts that control the machinability of cast steel and (2) determine the ability of ladle stirring to homogenize ladle temperature, reduce the tap and pouring temperatures, and reduce casting scrap.

  15. Roll Casting of Al-25%Si

    SciTech Connect (OSTI)

    Haga, Toshio [Osaka Institute of Technology, Omiya Asahiku Osaka city 535-8585 (Japan); Harada, Hideto [Graduate School of Osaka Institute of Technology, Omiya Asahiku Osaka city 535-8585 (Japan); Watari, Hisaki [Gunma University, Kiryu city, 376-8515 (Japan)

    2011-05-04

    Strip casting of Al-25%Si strip was tried using an unequal diameter twin roll caster. The diameter of the lower roll (large roll) was 1000 mm and the diameter of the upper roll (small roll) was 250 mm. Roll material was mild steel. The sound strip could be cast at the speeds ranging from 8 m/min to 12 m/min. The strip did not stick to the roll without the parting material. The primary Si, which existed at centre area of the thickness direction, was larger than that which existed at other area. The size of the primary Si was smaller than 0.2 mm. Eutectic Si was smaller 5 {mu}m. The as-cast strip was ranging from 2 mm to 3 mm thick and its width was 100 mm. The as-cast strip could be hot rolled down to 1 mm. The hot rolled strip was cold rolled. The primary Si became smaller and the pore occurred around the primary Si after the rolling.

  16. Mini-PROTEAN Multi-Casting Chamber

    E-Print Network [OSTI]

    Raizada, Manish N.

    Mini-PROTEAN® 3 Multi-Casting Chamber Instruction Manual Catalog Number 165-4110 For Technical components should be cleaned with a suitable laboratory detergent (Bio-Rad's Cleaning Concentrate, catalog number 161-0772), rinsed thoroughly with distilled water, and dried before use. Section 2 Loading

  17. MCWASP 2009 Edited by ... TMS (The Minerals, Metals & Materials Society), 2009

    E-Print Network [OSTI]

    Beckermann, Christoph

    is presented that predicts solid deformation and damage as well as melt pressure, feeding flow and shrinkage porosity during metal casting. A visco-plastic constitutive theory with damage is used to model the solid-purpose simulation codes. Novel steel casting experiments have been designed and performed which measure

  18. Exotherm data acquisition in polyurethane foam formation using a microcomputer

    SciTech Connect (OSTI)

    Hebrard, M.J.; Leroux, J.

    1986-01-01

    An Apple microcomputer was used to collect exotherm data of the reactions leading to the formation of polyurethane foams, to differentiate the curves with respect to time and to measure the position and magnitude of the inflection points. Hardware, software, operations and reproducibility of this automated data acquisition system are described.

  19. 1. Introduction Slag foaming consists of introducing gas bubbles into

    E-Print Network [OSTI]

    Pilon, Laurent

    that slag foaming could be more beneficial in steel production. Indeed, it provides a shield bubbled into molten CaO­SiO2­FeO­MgO­Al2O3 slags of various compositions contained in cylindrical tanks

  20. Development of Foamed Emulsion Bioreactor for Air Pollution Control

    E-Print Network [OSTI]

    Development of Foamed Emulsion Bioreactor for Air Pollution Control Eunsung Kan, Marc A. Deshusses: 10.1002/bit.10767 Abstract: A new type of bioreactor for air pollution con- trol has been developed. The new process relies on an organic-phase emulsion and actively growing pollutant- degrading

  1. Protein accumulation and distribution in floodplain soils and river foam

    E-Print Network [OSTI]

    Rilli, Matthias C.

    REPORT Protein accumulation and distribution in floodplain soils and river foam Mary J. Harner,1 of particular organisms is unknown. In this study, we explore how a Bradford-reactive soil protein (BRSP in Montana, we extracted BRSP from soils and related the protein concentrations to the age of soil surfaces

  2. Modeling triblock surfactant-templated mesostructured cellular foams Supriyo Bhattacharyaa

    E-Print Network [OSTI]

    Bhattacharya, Supriyo

    to understand the role of surfactant self-assembly in the synthesis of templated mesoporous materials, and inorganic oxide. Depending on the temperature and component concentrations, these systems phase separate to sphere transition associated with the synthesis of the mesostructured cellular foams MCFs . Pore size

  3. Self-lubricated transport of aqueous foams in horizontal conduits

    E-Print Network [OSTI]

    Joseph, Daniel D.

    1. Introduction Foams are encountered in many industrial applications; they are used as cleaning fluids, fire mitigators and in froth flotation in the paper and metallurgy industry. Many cosmetics in under-balanced drilling, for reservoir clean-up and for enhanced oil recovery in porous sand

  4. Environmentally-benign Flame Retardant Nanocoating for Foam and Fabric 

    E-Print Network [OSTI]

    Cain, Amanda Ashley

    2014-12-09

    for the purpose of inhibiting or suppressing the combustion cycle. Inspiration for first applying polymer/clay thin films (i.e., nanobrick walls) as flame retardant (FR) coatings to polyurethane foam via LbL came from the final stage of a proposed flame...

  5. 1 INTRODUCTION Flexible polyurethane foams are usually applied in

    E-Print Network [OSTI]

    Boyer, Edmond

    , producing polyurea and carbon dioxide, with simultaneous expansion of CO2 bubbles (foaming) and polymerization of the mixture. The first step of the expansion is bubble nucleation, where CO2 molecules chemical reactions take place: the first one creates CO2 into the fluid matrix (germination of bubbles

  6. Computer modeling of electromagnetic fields and fluid flows for edge containment in continuous casting

    SciTech Connect (OSTI)

    Chang, F.C.; Hull, J.R.; Wang, Y.H.; Blazek, K.E.

    1996-02-01

    A computer model was developed to predict eddy currents and fluid flows in molten steel. The model was verified by comparing predictions with experimental results of liquid-metal containment and fluid flow in electromagnetic (EM) edge dams (EMDs) designed at Inland Steel for twin-roll casting. The model can optimize the EMD design so it is suitable for application, and minimize expensive, time-consuming full-scale testing. Numerical simulation was performed by coupling a three-dimensional (3-D) finite-element EM code (ELEKTRA) and a 3-D finite-difference fluids code (CaPS-EM) to solve heat transfer, fluid flow, and turbulence transport in a casting process that involves EM fields. ELEKTRA is able to predict the eddy- current distribution and the electromagnetic forces in complex geometries. CaPS-EM is capable of modeling fluid flows with free surfaces. Results of the numerical simulation compared well with measurements obtained from a static test.

  7. Method of forming a relatively stable slip of silicon metal particles and yttrium containing particles

    DOE Patents [OSTI]

    Dickie, Ray A. (Birmingham, MI); Mangels, John A. (Flat Rock, MI)

    1984-01-01

    The method concerns forming a relatively stable slip of silicon metal particles and yttrium containing particles. In one embodiment, a casting slip of silicon metal particles is formed in water. Particles of a yttrium containing sintering aid are added to the casting slip. The yttrium containing sintering aid is a compound which has at least some solubility in water to form Y.sup.+3 ions which have a high potential for totally flocculating the silicon metal particles into a semiporous solid. A small amount of a fluoride salt is added to the casting slip which contains the yttrium containing sintering aid. The fluoride salt is one which will produce fluoride anions when dissolved in water. The small amount of the fluoride anions produced are effective to suppress the flocculation of the silicon metal particles by the Y.sup.+3 ions so that all particles remain in suspension in the casting slip and the casting slip has both an increased shelf life and can be used to cast articles having a relatively thick cross-section. The pH of the casting slip is maintained in a range from 7.5 to 9. Preferably, the fluoride salt used is one which is based on a monovalent cation such as sodium or ammonia. The steps of adding the yttrium containing sintering aid and the fluoride salt may be interchanged if desired, and the salt may be added to a solution containing the sintering aid prior to addition of the silicon metal particles.

  8. Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Development of Elevated Temperature Aluminum Metal Matrix Composite (MMC) Alloy and Its Processing Technology

    SciTech Connect (OSTI)

    Weiss, David C.; Gegal, Gerald A.

    2014-04-15

    The objective of this project was to provide a production capable cast aluminum metal matrix composite (MMC) alloy with an operating temperature capability of 250-300°C. Important industrial sectors as well as the military now seek lightweight aluminum alloy castings that can operate in temperature ranges of 250-300°C. Current needs in this temperature range are being satisfied by the use of titanium alloy castings. These have the desired strength properties but the end components are heavier and significantly more costly. Also, the energy requirements for production of titanium alloy castings are significantly higher than those required for production of aluminum alloys and aluminum alloy castings.

  9. Solar axion search with the CAST experiment

    E-Print Network [OSTI]

    CAST Collaboration; E. Arik; S. Aune; D. Autiero; K. Barth; A. Belov; B. Beltrán; S. Borghi; F. S. Boydag; H. Bräuninger; G. Cantatore; J. M. Carmona; S. A. Cetin; J. I. Collar; T. Dafni; M. Davenport; L. Di Lella; O. B. Dogan; C. Eleftheriadis; N. Elias; G. Fanourakis; E. Ferrer-Ribas; H. Fischer; J. Franz; J. Galán; E. Gazis; T. Geralis; I. Giomataris; S. Gninenko; H. Gómez; M. Hasinoff; F. H. Heinsius; I. Hikmet; D. H. H. Hoffmann; I. G. Irastorza; J. Jacoby; K. Jakov?i?; D. Kang; T. Karageorgopoulou; M. Karuza; K. Königsmann; R. Kotthaus; M. Kr?mar; K. Kousouris; M. Kuster; B. Laki?; C. Lasseur; A. Liolios; A. Ljubi?i?; V. Lozza; G. Lutz; G. Luzón; D. Miller; J. Morales; T. Niinikoski; A. Nordt; A. Ortiz; T. Papaevangelou; M. J. Pivovaroff; A. Placci; G. Raiteri; G. Raffelt; H. Riege; A. Rodríguez; J. Ruz; I. Savvidis; Y. Semertzidis; P. Serpico; S. K. Solanki; R. Soufli; L. Stewart; M. Tsagri; K. van Bibber; J5D. Villar; J. Vogel; L. Walckiers; K. Zioutas

    2008-10-10

    The CAST (CERN Axion Solar Telescope) experiment is searching for solar axions by their conversion into photons inside the magnet pipe of an LHC dipole. The analysis of the data recorded during the first phase of the experiment with vacuum in the magnet pipes has resulted in the most restrictive experimental limit on the coupling constant of axions to photons. In the second phase, CAST is operating with a buffer gas inside the magnet pipes in order to extent the sensitivity of the experiment to higher axion masses. We will present the first results on the $^{4}{\\rm He}$ data taking as well as the system upgrades that have been operated in the last year in order to adapt the experiment for the $^{3}{\\rm He}$ data taking. Expected sensitivities on the coupling constant of axions to photons will be given for the recent $^{3}{\\rm He}$ run just started in March 2008.

  10. Process for slip casting textured tubular structures

    DOE Patents [OSTI]

    Steinlage, Greg A. (West Lafayette, IN); Trumble, Kevin P. (West Lafayette, IN); Bowman, Keith J. (West Lafayette, IN)

    2002-01-01

    A process for centrifugal slip casting a textured hollow tube. A slip made up of a carrier fluid and a suspended powder is introduced into a porous mold which is rotated at a speed sufficient to create a centrifugal force that forces the slip radially outward toward the inner surface of the mold. The suspended powder, which is formed of particles having large dimensional aspect ratios such as particles of superconductive BSCCO, settles in a textured fashion radially outward toward the mold surface. The carrier fluid of the slip passes by capillary action radially outward around the settled particles and into the absorbent mold. A layer of mold release material is preferably centrifugally slip cast to cover the mold inner surface prior to the introduction of the BSCCO slip, and the mold release layer facilitates removal of the BSCCO greenbody from the mold without fracturing.

  11. Thin Wall Cast Iron: Phase II

    SciTech Connect (OSTI)

    Doru M. Stefanescu

    2005-07-21

    The development of thin-wall technology allows the designers of energy consuming equipment to select the most appropriate material based on cost/material properties considerations, and not solely on density. The technology developed in this research project will permit the designers working for the automotive industry to make a better informed choice between competing materials and thin wall cast iron, thus decreasing the overall cost of the automobile.

  12. Generalized entering coefficients: A criterion for foam stability against oil in porous media

    SciTech Connect (OSTI)

    Bergeron, V.; Fagan, M.E.; Radke, C.J.

    1993-09-01

    The unique mobility-control properties of foam in porous media make it an attractive choice as an injection fluid for enhanced oil recovery. Unfortunately, in many cases oil has a major destabilizing effect on foam. Therefore, it is important to understand how oil destabilizes foam and what surfactant properties lead to increased stability against oil. To explain the stability of foam in porous media in the presence of oil, we generalize the ideas of spreading and entering behavior using Frumkin-Deryaguin wetting theory. This formulation overcomes the inherent deficiencies in the classical spreading and entering coefficients used to explain foam stability against oil. We find that oil-tolerant foam can be produced by making the oil surface ``water wet``. To test our theoretical ideas, we measure foam-flow resistance through 45--70 {mu}m glass beadpacks, surface and interfacial tensions, and disjoining pressure isotherms for foam and pseudoemulsion films for a variety of surfactant/oil systems. Most notably, we measure pseudoemulsion-film disjoining pressure isotherms for the first time and directly establish that pseudoemulsion film stability controls the stability of the foam in the systems we tested. Moreover, we demonstrate the correspondence between stable pseudoemulsion films, negative entering behavior, and oil-tolerant foams.

  13. Centrifugal Casting Features/Metallurgical Characterization of Aluminum Alloys

    SciTech Connect (OSTI)

    Chirita, G.; Soares, D.; Cruz, D.; Silva, F. S. [Mechanical Engineering Department, School of Engineering, Minho University (Portugal); Stefanescu, I. [Faculty of Mechanical Engineering, Dunarea de Jos University Galati (Romania)

    2008-02-15

    This paper deals with the study of centrifugal effects on aluminium castings under high G values. Most of the studies in this domain (FGMs obtained by centrifugal casting) deal with functionally graded composites reinforced with a solid phase such as silicon particles or others. However, in this study it will be shown that unreinforced aluminium alloys may be significantly influenced by the centrifugal effect and that functionally graded castings are also obtained. It has been observed that the centrifugal effect may increase in some alloys, depending on the relative position in the castings, the rupture strength by approx. 50%, and rupture strain by about 300%, as compared to the gravity casting technique. The Young's modulus may also increase by about 20%. It has also been reported that in vertical centrifugal castings there are mainly three aspects that affect the components thus obtained, namely: fluid dynamics; vibration (inherent to the system); and centrifugal force. These features have a different effect on the castings depending on the aluminium alloy. In this paper, an analysis of the most important effects of the centrifugal casting process on metallurgical features is conducted. A solidification characterization at several points along the mould will be made in order to have an accurate idea of both the fluid dynamics inside the mould during the casting and the solidification behavior in different parts of the component. These two analyses will be related to the metallurgical properties (phase distribution; SDAS; eutectic silicon content and shape, pores density and shape) along the component and mainly along the direction of the centrifugal pressure. A comparison between castings obtained by both centrifugal casting technique and gravity casting technique is made for reference (gravity casting)

  14. Hickey, W8009C, casts 10-14,14A Hickey, W8009C, casts 10-14,14A, page 1

    E-Print Network [OSTI]

    Hickey, Barbara

    Hickey, W8009C, casts 10-14,14A Hickey, W8009C, casts 10-14,14A, page 1 #12;Hickey, W8009C, casts 10-14,14A Hickey, W8009C, casts 10-14,14A, page 2 #12;Hickey, W8009C, casts 10-14,14A Hickey, W8009C, casts 10-14,14A, page 3 #12;Hickey, W8009C, casts 10-14,14A Hickey, W8009C, casts 10-14,14A, page 4 #12

  15. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

    Fox, K. M.; Roberts, K. A.; Edwards, T. B.

    2014-02-28

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leachability indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste form. The thermal analyses completed in this study provide some preliminary insight, although the l

  16. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

    Fox, K. M.; Edwards, T. A.; Roberts, K. B.

    2013-10-02

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leach indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste form. The thermal analyses completed in this study provide some preliminary insight, although the limited

  17. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

    Fox, K. M.; Roberts, K. A.; Edwards, T. B.

    2013-09-17

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leach indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste form. The thermal analyses completed in this study provide some preliminary insight, although the limited

  18. Method of making metal matrix composites reinforced with ceramic particulates

    DOE Patents [OSTI]

    Cornie, J.A.; Kattamis, T.; Chambers, B.V.; Bond, B.E.; Varela, R.H.

    1989-08-01

    Composite materials and methods for making such materials are disclosed in which dispersed ceramic particles are at chemical equilibrium with a base metal matrix, thereby permitting such materials to be remelted and subsequently cast or otherwise processed to form net weight parts and other finished (or semi-finished) articles while maintaining the microstructure and mechanical properties (e.g. wear resistance or hardness) of the original composite. The composite materials of the present invention are composed of ceramic particles in a base metal matrix. The ceramics are preferably carbides of titanium, zirconium, tungsten, molybdenum or other refractory metals. The base metal can be iron, nickel, cobalt, chromium or other high temperature metal and alloys thereof. For ferrous matrices, alloys suitable for use as the base metal include cast iron, carbon steels, stainless steels and iron-based superalloys. 2 figs.

  19. Method of making metal matrix composites reinforced with ceramic particulates

    DOE Patents [OSTI]

    Cornie, James A. (North Chelmsford, MA); Kattamis, Theodoulos (Watertown, MA); Chambers, Brent V. (Cambridge, MA); Bond, Bruce E. (Bedford, MA); Varela, Raul H. (Canton, MA)

    1989-01-01

    Composite materials and methods for making such materials are disclosed in which dispersed ceramic particles are at chemical equilibrium with a base metal matrix, thereby permitting such materials to be remelted and subsequently cast or otherwise processed to form net weight parts and other finished (or semi-finished) articles while maintaining the microstructure and mechanical properties (e.g. wear resistance or hardness) of the original composite. The composite materials of the present invention are composed of ceramic particles in a base metal matrix. The ceramics are preferably carbides of titanium, zirconium, tungsten, molybdenum or other refractory metals. The base metal can be iron, nickel, cobalt, chromium or other high temperature metal and alloys thereof. For ferrous matrices, alloys suitable for use as the base metal include cast iron, carbon steels, stainless steels and iron-based superalloys.

  20. Effects of quantum space time foam in the neutrino sector

    E-Print Network [OSTI]

    H. V. Klapdor-Kleingrothaus; H. Päs; U. Sarkar

    2000-07-05

    We discuss violations of CPT and quantum mechanics due to interactions of neutrinos with space-time quantum foam. Neutrinoless double beta decay and oscillations of neutrinos from astrophysical sources (supernovae, active galactic nuclei) are analysed. It is found that the propagation distance is the crucial quantity entering any bounds on EHNS parameters. Thus, while the bounds from neutrinoless double beta decay are not significant, the data of the supernova 1987a imply a bound being several orders of magnitude more stringent than the ones known from the literature. Even more stringent limits may be obtained from the investigation of neutrino oscillations from active galactic nuclei sources, which have an impressive potential for the search of quantum foam interactions in the neutrino sector.

  1. Calibrating the Abaqus Crushable Foam Material Model using UNM Data

    SciTech Connect (OSTI)

    Schembri, Philip E.; Lewis, Matthew W.

    2014-02-27

    Triaxial test data from the University of New Mexico and uniaxial test data from W-14 is used to calibrate the Abaqus crushable foam material model to represent the syntactic foam comprised of APO-BMI matrix and carbon microballoons used in the W76. The material model is an elasto-plasticity model in which the yield strength depends on pressure. Both the elastic properties and the yield stress are estimated by fitting a line to the elastic region of each test response. The model parameters are fit to the data (in a non-rigorous way) to provide both a conservative and not-conservative material model. The model is verified to perform as intended by comparing the values of pressure and shear stress at yield, as well as the shear and volumetric stress-strain response, to the test data.

  2. Equipment compatibility and logistics assessment for containment foam deployment.

    SciTech Connect (OSTI)

    McRoberts, Vincent M.; Martell, Mary-Alena; Jones, Joseph A.

    2005-09-01

    The deployment of the Joint Technical Operations Team (JTOT) is evolving toward a lean and mobile response team. As a result, opportunities to support more rapid mobilization are being investigated. This study investigates three specific opportunities including: (1) the potential of using standard firefighting equipment to support deployment of the aqueous foam concentrate (AFC-380); (2) determining the feasibility and needs for regional staging of equipment to reduce the inventory currently mobilized during a JTOT response; and (3) determining the feasibility and needs for development of the next generation AFC-380 to reduce the volume of foam concentrate required for a response. This study supports the need to ensure that requirements for alternative deployment schemes are understood and in place to support improved response activities.

  3. Comments on Cahill's Quantum Foam Inflow Theory of Gravity

    E-Print Network [OSTI]

    T. D. Martin

    2004-07-20

    We reveal an underlying flaw in Reginald T. Cahill's recently promoted quantum foam inflow theory of gravity. It appears to arise from a confusion of the idea of the Galilean invariance of the acceleration of an individual flow with what is obtained as an acceleration when a homogeneous flow is superposed with an inhomogeneous flow. We also point out that the General Relativistic covering theory he creates by substituting a generalized Painleve-Gullstrand metric into Einstein's field equations leads to absurd results.

  4. Foaming of E-Glass II (Report for G Plus Project for PPG)

    E-Print Network [OSTI]

    Pilon, Laurent

    nearly linearly with the heating rate and no foam was produced when CO2 + 55% H2O atmosphere was introduced at 300°C. It was shown that the lack of foaming in the test with CO2 + 55% H2O atmospherePNNL-15394 Foaming of E-Glass II (Report for G Plus Project for PPG) D.-S. Kim M. Portch J. Matyas

  5. Process Physics: From Quantum Foam to General Relativity

    E-Print Network [OSTI]

    Reginald T. Cahill

    2002-03-05

    Progress in the new information-theoretic process physics is reported in which the link to the phenomenology of general relativity is made. In process physics the fundamental assumption is that reality is to be modelled as self-organising semantic (or internal or relational) information using a self-referentially limited neural network model. Previous progress in process physics included the demonstration that space and quantum physics are emergent and unified, with time a distinct non-geometric process, that quantum phenomena are caused by fractal topological defects embedded in and forming a growing three-dimensional fractal process-space, which is essentially a quantum foam. Other features of the emergent physics were: quantum field theory with emergent flavour and confined colour, limited causality and the Born quantum measurement metarule, inertia, time-dilation effects, gravity and the equivalence principle, a growing universe with a cosmological constant, black holes and event horizons, and the emergence of classicality. Here general relativity and the technical language of general covariance is seen not to be fundamental but a phenomenological construct, arising as an amalgam of two distinct phenomena: the `gravitational' characteristics of the emergent quantum foam for which `matter' acts as a sink, and the classical `spacetime' measurement protocol, but with the later violated by quantum measurement processes. Quantum gravity, as manifested in the emergent Quantum Homotopic Field Theory of the process-space or quantum foam, is logically prior to the emergence of the general relativity phenomenology, and cannot be derived from it.

  6. Explosively driven low-density foams and powders

    DOE Patents [OSTI]

    Viecelli, James A. (Orinda, CA); Wood, Lowell L. (Simi Valley, CA); Ishikawa, Muriel Y. (Livermore, CA); Nuckolls, John H. (Danville, CA); Pagoria, Phillip F. (Livermore, CA)

    2010-05-04

    Hollow RX-08HD cylindrical charges were loaded with boron and PTFE, in the form of low-bulk density powders or powders dispersed in a rigid foam matrix. Each charge was initiated by a Comp B booster at one end, producing a detonation wave propagating down the length of the cylinder, crushing the foam or bulk powder and collapsing the void spaces. The PdV work done in crushing the material heated it to high temperatures, expelling it in a high velocity fluid jet. In the case of boron particles supported in foam, framing camera photos, temperature measurements, and aluminum witness plates suggest that the boron was completely vaporized by the crush wave and that the boron vapor turbulently mixed with and burned in the surrounding air. In the case of PTFE powder, X-ray photoelectron spectroscopy of residues recovered from fragments of a granite target slab suggest that heating was sufficient to dissociate the PTFE to carbon vapor and molecular fluorine which reacted with the quartz and aluminum silicates in the granite to form aluminum oxide and mineral fluoride compounds.

  7. AMD 405: Improved Automotive Suspension Components Cast with...

    Office of Energy Efficiency and Renewable Energy (EERE) Indexed Site

    alloy to cast as it is sensitive to cooling rate and is susceptible to hot tearing. Stress Corrosion Cracking (SCC) and Heat Treatment Evaluate new, quicker, alternative...

  8. AIS/DOE Technology Roadmap Program: Strip Casting: Anticipating...

    Office of Scientific and Technical Information (OSTI)

    AISDOE Technology Roadmap Program: Strip Casting: Anticipating New Routes To Steel Sheet Citation Details In-Document Search Title: AISDOE Technology Roadmap Program: Strip...

  9. Microstructural Modification of a Cast Iron by Magnetic Field Processing

    SciTech Connect (OSTI)

    Kenik, Edward A [ORNL; Ludtka, Gail Mackiewicz- [ORNL; Ludtka, Gerard Michael [ORNL; Wilgen, John B [ORNL; Kisner, Roger A [ORNL

    2010-01-01

    The current study deals with the microstructural modification of a nodular cast iron during solidification under the influence of high magnetic fields (up to 18 tesla).

  10. The use of coated micropowders to reduce radiation heat transfer in foam insulation

    E-Print Network [OSTI]

    Marge, Arlene Lanciani

    1991-01-01

    Polyurethane foam is the most effective insulation currently available for buildings. Chlorofluorocarbon (CFC) blowing agents, which have low thermal conductivities, contribute highly to the effectiveness of this insulation. ...

  11. Synthesis of Mesocellular Silica Foams with Tunable Window and Cell Dimensions

    E-Print Network [OSTI]

    Yang, Peidong

    Polystyrene microspheres coated with cationic surfactants are easily prepared by micro- emulsion templates. These silica foams resemble dense aerogels. Introduction Because of their greatly enhanced pore

  12. Pitch-based carbon foam heat sink with phase change material

    DOE Patents [OSTI]

    Klett, James W. (Knoxville, TN); Burchell, Timothy D. (Oak Ridge, TN)

    2000-01-01

    A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

  13. Pitch-based carbon foam heat sink with phase change material

    DOE Patents [OSTI]

    Klett, James W. (Knoxville, TN); Burchell, Timothy D. (Oak Ridge, TN)

    2002-01-01

    A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

  14. Assessment of Computer Simulation Software and Process Data for High Pressure Die Casting of Magnesium

    SciTech Connect (OSTI)

    Sabau, Adrian S; Hatfield, Edward C; Dinwiddie, Ralph Barton; Kuwana, Kazunori; Viti, Valerio; Hassan, Mohamed I; Saito, Kozo

    2007-09-01

    Computer software for the numerical simulation of solidification and mold filling is an effective design tool for cast structural automotive magnesium components. A review of commercial software capabilities and their validation procedures was conducted. Aside form the software assessment, the program addressed five main areas: lubricant degradation, lubricant application, gate atomization, and heat transfer at metal mold interfaces. A test stand for lubricant application was designed. A sensor was used for the direct measurement of heat fluxes during lubricant application and casting solidification in graphite molds. Spray experiments were conducted using pure deionized water and commercial die lubricants. The results show that the sensor can be used with confidence for measuring heat fluxes under conditions specific to the die lube application. The data on heat flux was presented in forms suitable for use in HPDC simulation software. Severe jet breakup and atomization phenomena are likely to occur due to high gate velocities in HPDC. As a result of gate atomization, droplet flow affects the mold filling pattern, air entrapment, skin formation, and ensuing defects. Warm water analogue dies were designed for obtaining experimental data on mold filling phenomena. Data on break-up jet length, break-up pattern, velocities, and droplet size distribution were obtained experimentally and was used to develop correlations for jet break-up phenomena specific to die casting gate configurations.

  15. A Numerical Model of the Temperature Field of the Cast and Solidified Ceramic Material

    SciTech Connect (OSTI)

    Kavicka, Frantisek; Sekanina, Bohumil; Stransky, Karel; Stetina, Josef [Brno University of Technology, Brno, Technicka 2 (Czech Republic); Dobrovska, Jana [Technical University of Ostrava, Ostrava, Tr. 17.listopadu 17 (Czech Republic)

    2010-06-15

    Corundo-baddeleyit material (CBM)--EUCOR--is a heat- and wear-resistant material even at extreme temperatures. This article introduces a numerical model of solidification and cooling of this material in a non-metallic mould. The model is capable of determining the total solidification time of the casting and also the place of the casting which solidifies last. Furthermore, it is possible to calculate the temperature gradient in any point and time, and also determine the local solidification time and the solidification interval of any point. The local solidification time is one of the input parameters for the cooperating model of chemical heterogeneity. This second model and its application on samples of EUCOR prove that the applied method of measurement of chemical heterogeneity provides detailed quantitative information on the material structure and makes it possible to analyse the solidification process. The analysis of this process entails statistical processing of the results of the measurements of the heterogeneity of the components of EUCOR and performs correlation of individual components during solidification. The crystallisation process seems to be very complicated, where the macro- and microscopic segregations differ significantly. The verification of both numerical models was conducted on a real cast 350x200x400 mm block.

  16. Fatigue Life Prediction in Rapid Die Casting - Preliminary Work in View of Current Research

    SciTech Connect (OSTI)

    Chuan Huat Ng [Faculty of Mechanical and Manufacturing Engineering (FKMP), Kolej Universiti Teknologi Tun Hussein Onn (KUiTTHO), P.O.Box 101, 86400 Parit Raja, Batu Pahat, Johor (Malaysia); Grote, Karl-Heinrich [Institut fuer Maschinenkonstruktion, Lehrstuhl Konstruktionstechnik, Otto-von-Guericke University Magdeburg, Universitaetsplatz 2, 39106 Magdeburg (Germany); Baehr, Ruediger [Institut fuer Fertigungstechnik und Qualitaetssicherung, Ur und Umformtechnik, Otto-von-Guericke University Magdeburg, Universitaetsplatz 2, 39106 Magdeburg (Germany)

    2007-05-17

    Numerical simulation technique as a prediction tool is slowly adopted in metal casting industry for predicting design modelling solidification analysis. The reasons for this activity is found in the need to further enhance the geometrical design and mechanical properties of the tool design and the correct prediction methodology to fulfil industrial needs. The present state of numerical simulation capabilities in rapid die casting technologies is reviewed and the failure mode mechanisms of thermal fatigue, aimed at developing a numerical simulation with a systematic design guidance for predicting the thermal cyclic loading analysis and improvement is presented along with several other methods. The economic benefits of a numerical simulation technique in die casting are limited to tool life time, mechanical properties and design guidance. The extensive computer capabilities of a numerical simulation with a systematic design guidance methodology are exploited to provide a solution for flexible design, mechanical properties and mould life time. Related research carried out worldwide by different organisations and academic institutions are discussed.

  17. SmartCast - Novel Textile Sensors for Embedded Pressure Sensing of Orthopedic Casts

    E-Print Network [OSTI]

    Danilovic, Andrew

    2013-01-01

    set_sleep_mode(SLEEP_MODE_PWR_DOWN); //enter Power-down Mode4 #define SEL2_PB0 8 #define SEL1_PD7 7 #define PWR_CTRL_PINPD5 #define PWR_CTRL_SD_CARD 6 //SmartCast bitFields for

  18. Method and apparatus for strip casting

    DOE Patents [OSTI]

    Follstaedt, Donald W. (Middletown, OH); Powell, John C. (Pittsburgh, PA); Sussman, Richard C. (West Chester, OH); Williams, Robert S. (Fairfield, OH)

    1991-01-01

    Casting nozzles will provide improved flow conditions with the parameters controlled according to the present invention. The gap relationships between the nozzle slot and exit orifice must be controlled in combination with converging exit passageway to provide a smooth flow without shearing and turbulence in the stream. The nozzle lips are also rounded to improve flow and increase refractory life of the lips of the nozzle. The tundish walls are tapered to provide improve flow for supplying the melt to the nozzle. The nozzle is located about 45.degree. below top dead center for optimum conditions.

  19. Continuation of Crosscutting Technology Development at Cast

    SciTech Connect (OSTI)

    Yoon, Roe-Hoan

    2012-03-31

    This Final Technical Report describes progress made on the sub-projects awarded in the Cooperative Agreement DE-FC26-05NT42457: Continuation of Crosscutting Technology Development at Center for Advanced Separation Technologies (CAST). The final reports for each sub-project are attached in the appendix. Much of the research to be conducted with Cooperative Agreement funds will be longer-term, high-risk, basic research and will be carried out in five broad areas: a) Solid-solid separation b) Solid-liquid separation c) Chemical/Biological Extraction d) Modeling and Control, and e) Environmental Control.

  20. Phase Transformations in Cast Duplex Stainless Steels

    SciTech Connect (OSTI)

    Yoon-Jun Kim

    2004-12-19

    Duplex stainless steels (DSS) constitute both ferrite and austenite as a matrix. Such a microstructure confers a high corrosion resistance with favorable mechanical properties. However, intermetallic phases such as {sigma} and {chi} can also form during casting or high-temperature processing and can degrade the properties of the DSS. This research was initiated to develop time-temperature-transformation (TTT) and continuous-cooling-transformation (CCT) diagrams of two types of cast duplex stainless steels, CD3MN (Fe-22Cr-5Ni-Mo-N) and CD3MWCuN (Fe-25Cr-7Ni-Mo-W-Cu-N), in order to understand the time and temperature ranges for intermetallic phase formation. The alloys were heat treated isothermally or under controlled cooling conditions and then characterized using conventional metallographic methods that included tint etching, and also using electron microscopy (SEM, TEM) and wavelength dispersive spectroscopy (WDS). The kinetics of intermetallic-phase ({sigma} + {chi}) formation were analyzed using the Johnson-Mehl-Avrami (MA) equation in the case of isothermal transformations and a modified form of this equation in the case of continuous cooling transformations. The rate of intermetallic-phase formation was found to be much faster in CD3MWCuN than CD3MN due mainly to differences in the major alloying contents such as Cr, Ni and Mo. To examine in more detail the effects of these elements of the phase stabilities; a series of eight steel castings was designed with the Cr, Ni and Mo contents systematically varied with respect to the nominal composition of CD3MN. The effects of varying the contents of alloying additions on the formation of intermetallic phases were also studied computationally using the commercial thermodynamic software package, Thermo-Calc. In general, {sigma} was stabilized with increasing Cr addition and {chi} by increasing Mo addition. However, a delicate balance among Ni and other minor elements such as N and Si also exists. Phase equilibria in DSS can be affected by local composition fluctuations in the cast alloy. This may cause discrepancy between thermodynamic prediction and experimental observation.