Sample records for foam metal casting

  1. Clean Metal Casting

    SciTech Connect (OSTI)

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05T23:59:59.000Z

    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.

  2. Nanostructured metal foams: synthesis and applications

    SciTech Connect (OSTI)

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

    2009-01-01T23:59:59.000Z

    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.

  3. Low density metal hydride foams

    DOE Patents [OSTI]

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

    1991-01-01T23:59:59.000Z

    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.

  4. Improvement of the Lost Foam Casting Process | Department of Energy

    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 DataDepartment of Energy Your Density Isn't YourTransport(Fact Sheet),EnergyImprovement of the Lost Foam Casting Process Improvement of

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

    SciTech Connect (OSTI)

    Ronald Michaels

    2005-09-30T23:59:59.000Z

    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.

  6. 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

    2011-07-31T23:59:59.000Z

    This project was a subtask of Energy Saving Melting and Revert Reduction Technology (√?¬Ę√?¬?√?¬?Energy SMARRT√?¬Ę√?¬?√?¬Ě) 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√?¬Ę√?¬?√?¬?s/year and 6.46 trillion BTU√?¬Ę√?¬?√?¬?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).

  7. 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 &...

  8. 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...

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

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

    Metal Casting: Corrosion Testing Practices - High Alloy Corrosion Program ITP Metal Casting: Corrosion Testing Practices - High Alloy Corrosion Program lehighfs.pdf More Documents...

  10. 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)

    1987-01-01T23:59:59.000Z

    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.

  11. 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)

    1988-01-01T23:59:59.000Z

    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.

  12. 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 [CanmetMATERIALS] [CanmetMATERIALS; Griffin, John A. [University of Alabama - Birmingham] [University of Alabama - Birmingham

    2014-03-31T23:59:59.000Z

    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.

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

    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 DataDepartment of Energy Your Density Isn't YourTransport(Fact Sheet), GeothermalGridHYDROGENDDepartmentSeptember 20092009casting Industry

  14. The response of clamped sandwich plates with metallic foam cores to simulated blast loading

    E-Print Network [OSTI]

    Fleck, Norman A.

    projectiles. The sandwich plates comprise AISI 304 stainless steel face sheets and aluminium alloy metal foam

  15. Spray casting of metallic preforms

    DOE Patents [OSTI]

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

    2000-01-01T23:59:59.000Z

    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.

  16. 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)

    2012-05-08T23:59:59.000Z

    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.

  17. Innovative Technologies to Manufacture Hybrid Metal Foam/Composite Components

    SciTech Connect (OSTI)

    Carrino, L.; Durante, M.; Franchitti, S. [DIMP, University of Naples 'Federico II', P.le Tecchio, 80-80125 Naples (Italy); Sorrentino, L.; Tersigni, L. [DII, University of Cassino, Via G. Di Biasio, 43-03043 Cassino (Italy)

    2011-01-17T23:59:59.000Z

    The aim of this paper is to verify the technological feasibility to realize hybrid metal-foam/composite component and the mechanical performances of the final structure. The hybrid component is composed by a cylindrical core in aluminum foam, the most used between those commercially available, and an outer layer in epoxy/S2-glass, manufactured by filament winding technology.A set of experimental tests have been carried out, to the aim to estimate the improvement of the hybrid component characteristics, compared to the sum of the single components (metal foam cylinder and epoxy/S2-glass tube).

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

    DOE Patents [OSTI]

    Nunez, Luis; Kaminski, Michael Donald

    2007-01-23T23:59:59.000Z

    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.

  19. Mechanical Properties of a Metal Powder-Loaded Polyurethane Foam

    SciTech Connect (OSTI)

    C. L. Neuschwanger; L. L. Whinnery; S. H. Goods

    1999-04-01T23:59:59.000Z

    Quasi-static compression tests have been performed on polyurethane foam specimens. The modulus of the foam exhibited a power-law dependence with respect to density of the form: E* {proportional_to} {rho}*{sup n}, where n = 1.7. The modulus data is well described by a simple geometric model (attributed to the work of Gibson and Ashby) for closed-cell foam in which the stiffness of the foam is governed by the flexure of the cell struts and cell walls. The compressive strength of the foam is also found to follow a power-law behavior with respect to foam density. In this instance, Euler buckling is used to rationalize the density dependence. The modulus of the polyurethane foam was modified by addition of a gas atomized, spherical aluminum powder. Additions of 30 and 50 weight percent of the powder significantly increased the foam modulus. However, there were only slight increases in modulus with 5 and 10 weight percent additions of the metal powder. Strength was also slightly increased at high loading fractions of powder. This increase in modulus and strength could be predicted by combining the above geometric model with a well-known model describing the effect on modulus of a rigid dispersoid in a compliant matrix.

  20. 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 2012 DOE Hydrogen and Fuel Cells Program and Vehicle Technologies Program Annual Merit Review and Peer Evaluation...

  1. Method and mold for casting thin metal objects

    DOE Patents [OSTI]

    Pehrson, Brandon P; Moore, Alan F

    2014-04-29T23:59:59.000Z

    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.

  2. Preparation of nanoporous metal foam from high nitrogen transition metal complexes

    DOE Patents [OSTI]

    Tappan, Bryce C.; Huynh, My Hang V.; Hiskey, Michael A.; Son, Steven F.; Oschwald, David M.; Chavez, David E.; Naud, Darren L.

    2006-11-28T23:59:59.000Z

    Nanoporous metal foams are prepared by ignition of high nitrogen transition metal complexes. The ammonium salts of iron(III) tris[bi(tetrazolato)-amine], cobalt(III) tris(bi(tetrazolato)amine), and high nitrogen compounds of copper and silver were prepared as loose powders, pressed into pellets and wafers, and ignited under an inert atmosphere to form nanoporous metal foam monoliths having very high surface area and very low density.

  3. Material accountancy for metallic fuel pin casting

    SciTech Connect (OSTI)

    Bucher, R.G.; Orechwa, Y.; Beitel, J.C.

    1995-08-01T23:59:59.000Z

    The operation of the Fuel Conditioning Facility (FCF) is based on the electrometallurgical processing of spent metallic reactor fuel. The pin casting operation, although only one of several operations in FCF, was the first to be on-line. As such, it has served to demonstrate the material accountancy system in many of its facets. This paper details, for the operation of the pin casting process with depleted uranium, the interaction between the mass tracking system (MTG) and some of the ancillary computer codes which generate pertinent information for operations and material accountancy. It is necessary to distinguish between two types of material balance calculations -- closeout for operations and material accountancy for safeguards. The two have much in common, for example, the mass tracking system database and the calculation of an inventory difference, but, in general, are not congruent with regard to balance period and balance spatial domain. Moreover, the objective, assessment, and reporting requirements of the calculated inventory difference are very different in the two cases.

  4. Metallic Fuel Casting Development and Parameter Optimization Simulations

    SciTech Connect (OSTI)

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

    2013-03-01T23:59:59.000Z

    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.

  5. Filler metal alloy for welding cast nickel aluminide alloys

    DOE Patents [OSTI]

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

    1998-03-10T23:59:59.000Z

    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.

  6. Cast Metal Coalition Research and Development Closeout Report

    SciTech Connect (OSTI)

    Allen, D.

    2000-08-01T23:59:59.000Z

    The Cast Metal Coalition, composed of more than 22 research providers and universities and 149 industrial partners, has completed a four-year research and development partnership with the Department of Energy. This report provides brief summaries of the 29 projects performed by the Coalition. These projects generated valuable information in such aspects of the metals industry as process prediction technologies, quality control, improved alloys, product machinability, and casting process improvements.

  7. Forming foam structures with carbon foam substrates

    DOE Patents [OSTI]

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

    2012-11-06T23:59:59.000Z

    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.

  8. 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 make them excellent candidates for a variety of thermofluid applications including fuel cells, compact

  9. 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.

    2005-09-01T23:59:59.000Z

    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.

  10. Synthesis method for amorphous metallic foam Jan Schroersa)

    E-Print Network [OSTI]

    Haller, Gary L.

    be classified as ei- ther open or closed porous. Open foams are characterized by interconnected bubbles

  11. 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)

    2002-11-05T23:59:59.000Z

    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.

  12. Manufacturers Saving with Lost Foam Metal Casting | Department of Energy

    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 DataDepartment of Energy Your Density Isn't YourTransport(FactDepartment ofLetterEconomyDr.Energy UniversityOversight

  13. Nuclear-waste encapsulation by metal-matrix casting

    SciTech Connect (OSTI)

    Nelson, R.G.; Nesbitt, J.F.; Slate, S.C.

    1981-05-01T23:59:59.000Z

    Several encapsulation casting processes are described that were developed or used at the Pacific Northwest Laboratory to embed simulated high-level wastes of two different forms (glass marbles and ceramic pellets) in metal matrices. Preliminary evaluations of these casting processes and the products are presented. Demonstrations have shown that 5- to 10-mm-dia glass marbles can be encapsulated on an engineering scale with lead or lead alloys by gravity or vacuum processes. Marbles approx. 12 mm in dia were successfully encapsulated in a lead alloy on a production scale. Also, 4- to 9-mm-dia ceramic pellets in containers of various sizes were completely penetrated and the individual pellets encased with aluminum-12 wt % silicon alloy by vacuum processes. Indications are that of the casting processes tested, aluminum 12 wt % silicon alloy vacuum-cast around ceramic pellets had the highest degree of infiltration or coverage of pellet surfaces.

  14. Electromagnetic augmentation for casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, J.R.

    1987-10-28T23:59:59.000Z

    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.

  15. Research Plan: Foam Delivery of Remedial Amendments to Deep Vadose Zone for Metals and Radionuclides Remediation

    SciTech Connect (OSTI)

    Zhong, Lirong; Hart, Andrea T.; Szecsody, James E.; Zhang, Z. F.; Freedman, Vicky L.; Ankeny, Mark; Hull, Laurence; Oostrom, Martinus; Freshley, Mark D.; Wellman, Dawn M.

    2009-01-16T23:59:59.000Z

    Research proposals were submitted to the Scientific and Technical Basis for In Situ Treatment of Metals and Radionuclides Technical Working Group under the US Department of Energy (DOE) Environmental Management Office (specifically, EM-22). After a peer review and selection process, the proposal, ďFoam Delivery of Remedial Amendments to Deep Vadose Zone for Metals and Radionuclides Remediation,Ē submitted by Pacific Northwest National Laboratory (PNNL) was selected for support by the program. A research plan was requested for this EM funded project. The overall objective of this project is to develop foam delivery technology for the distribution of remedial amendments to deep vadose zone sediments for in situ immobilization of metal and radionuclide contaminants. The focus of this research in FY 2009 is on the physical aspects of the foam delivery approach. Specific objectives are to 1) study the foam quality (i.e. the gas volume fraction in foam) influence on injection pressure, 2) study the sediment air permeability influence on injection pressure, 3) investigate liquid uptake in sediment and determine whether a water front will be formed during foam delivery, 4) test amendment distance (and mass) delivery by foam from the injection point, 5) study the enhanced sweeping over heterogeneous systems (i.e., low K zones) by foam delivery relative to water-based delivery under vadose zone conditions, and 6) numerically simulate foam delivery processes in the vadose zone. Laboratory scale experiments will be conducted at PNNL to study a range of basic physical aspects of the foam propagation in sediments, including foam quality and sediment permeability influence on injection pressure, liquid uptake, and foam sweeping across heterogeneous systems. This study will be augmented with separate studies to be conducted at MSE Technology Applications, Inc. (MSE) to evaluate foam transport and amendment delivery at the intermediate-scale. The results of intermediate-scale tests will be used to bridge the gap between the small-scale foam transport studies and the field-scale demonstration. Numerical simulation studies on foam delivery under vadose conditions will be performed to simulate observed foam transport behavior under vadose zone conditions and predict the foam delivery performance at field-scale.

  16. Filler metal alloy for welding cast nickel aluminide alloys

    DOE Patents [OSTI]

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

    1998-01-01T23:59:59.000Z

    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.

  17. Electromagnetic augmentation for casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, John R. (Hinsdale, IL)

    1989-01-01T23:59:59.000Z

    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.

  18. Stochastic Characterization of Cast Metal Microstructure

    SciTech Connect (OSTI)

    Steinzig, M.

    1999-06-01T23:59:59.000Z

    The major goal of this work is to provide a means to characterize the final structure of a metal that has solidified from a melt. The thermally controlled solidification of a binary alloy, nucleated at isolated sites, is described by the evolution of a probability distribution function (PDF). The relevant equation required for propagating the PDF is developed with variables for grain size and distance to nearest neighbor. The phenomena of nucleation, growth, and impingement of the grains are discussed, and used as the basis for developing rate equations that evolve the PDF. The complementary equations describing global heat and solute transfer are discussed, and coupled with the microstructure evolution equations for grain growth and PDF evolution. The full set of equations is solved numerically and results are compared with experimental data for the plutonium 1 weight percent gallium system. The three principal results of this work are: (1) The formulation of transient evolution equations for the PDF description of nucleation, growth, and impingement of a distribution of grain sizes and locations; (2) Solution of the equations to give a correlation for final average grain size as a function of material parameters, nucleation site density, and cooling rate; and (3) Solution of the equations for final distribution of grain size as a result of the initial random spatial distribution of nucleation sites.

  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)

    1991-01-01T23:59:59.000Z

    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. Cast Metals Coalition Technology Transfer and Program Management Final Report

    SciTech Connect (OSTI)

    Gwyn, Mike

    2009-03-31T23:59:59.000Z

    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.

  1. The response of clamped sandwich plates with metallic foam cores to simulated blast D.D. Radford, G.J. McShane, V.S. Deshpande and N.A. Fleck

    E-Print Network [OSTI]

    Fleck, Norman A.

    projectiles. The sandwich plates comprise AISI 304 stainless steel face sheets and aluminium alloy metal foam

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

    DOE Patents [OSTI]

    Meyer, Thomas N. (Murrysville, PA)

    2004-06-01T23:59:59.000Z

    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.

  3. National Metal Casting Research Institute final report. Volume 2, Die casting research

    SciTech Connect (OSTI)

    Jensen, D. [University of Northern Iowa, Cedar Falls, IA (United States). Dept. of Industrial Technology] [comp.

    1994-06-01T23:59:59.000Z

    Four subprojects were completed: development and evaluation of die coatings, accelerated die life characterization of die materials, evaluation of fluid flow and solidification modeling programs, selection and characterization of Al-based die casting alloys, and influence of die materials and coatings on die casting quality.

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

    E-Print Network [OSTI]

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

    motor burnouts occur because of some other failure which increases ~otor temperature. Electricity and Deregulation The metal casting business is a large electrica user. Deregulation and contracting for electricity will cjlange how plants optimize...

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

    SciTech Connect (OSTI)

    Fasoyinu, Yemi [CanmetMATERIALS] [CanmetMATERIALS

    2014-03-31T23:59:59.000Z

    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.

  6. 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)

    2003-06-17T23:59:59.000Z

    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.

  7. Composite carbon foam electrode

    DOE Patents [OSTI]

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

    1997-05-06T23:59:59.000Z

    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.

  8. Composite carbon foam electrode

    DOE Patents [OSTI]

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

    1997-01-01T23:59:59.000Z

    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.

  9. ''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

    2001-12-14T23:59:59.000Z

    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.

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

    SciTech Connect (OSTI)

    Villa, Andrea; Mussi, Valerio [Laboratorio MUSP-via Turotti 9, 29122 Piacenza (Italy); Strano, Matteo [Politecnico di Milano-Dipartimento di Meccanica, via La Masa 1, 20156, Milan (Italy)

    2011-05-04T23:59:59.000Z

    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.

  11. Synthesis of bulk metallic glass foam by powder extrusion with a fugitive second phase

    SciTech Connect (OSTI)

    Lee, Min Ha; Sordelet, Daniel J. [Materials and Engineering Physics Program, Ames Laboratory, Iowa State University, Ames, Iowa 50011 (United States)

    2006-07-10T23:59:59.000Z

    Bulk metallic glass foams with 12 mm in diameter and 30 mm in length having a density of 4.62 g/cm{sup 3} (approximately 58.3% of theoretical) were fabricated by extruding a powder mixture comprised of 60 vol % Ni{sub 59}Zr{sub 20}Ti{sub 16}Si{sub 2}Sn{sub 3} metallic glass blended with 40 vol % brass followed by dissolution of the fugitive brass in an aqueous HNO{sub 3} solution. The final structure consists of continuously connected, high aspect ratio metallic glass struts surrounded by {approx}40 vol % of homogeneously distributed ellipsoid-shaped pores having nominal diameters between 10 and 50 {mu}m.

  12. ITP Metal Casting: Metalcasting Industry Technology Roadmap | 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 DataDepartment of Energy Your Density Isn't YourTransport(Fact Sheet), GeothermalGridHYDROGENDDepartmentSeptember 20092009casting

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

    DOE Patents [OSTI]

    Kuznetsov, S.B.

    1986-04-01T23:59:59.000Z

    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.

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

    DOE Patents [OSTI]

    Kuznetsov, Stephen B. (Pittsburgh, PA)

    1986-01-01T23:59:59.000Z

    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.

  15. Non-Darcy natural convection in high porosity metal foams M.S. Phanikumar a,*, R.L. Mahajan b

    E-Print Network [OSTI]

    ≠Forchheimer-extended Darcy flow model and a semi-heuristic two-equation energy model obtained by relaxing the local thermalNon-Darcy natural convection in high porosity metal foams M.S. Phanikumar a,*, R.L. Mahajan b but only a heated plate. Thermal dispersion effects and the effects of Darcy number on heat transfer

  16. 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)

    1989-03-21T23:59:59.000Z

    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.

  17. REFORMULATION OF COAL-DERIVED TRANSPORTATION FUELS: SELECTIVE OXIDATION OF CARBON MONOXIDE ON METAL FOAM CATALYSTS

    SciTech Connect (OSTI)

    Mr. Paul Chin; Dr. Xiaolei Sun; Professor George W. Roberts; Professor James J. Spivey; Mr. Amornmart Sirijarhuphan; Dr. James G. Goodwin, Jr.; Dr. Richard W. Rice

    2002-12-31T23:59:59.000Z

    Several different catalytic reactions must be carried out in order to convert hydrocarbons (or alcohols) into hydrogen for use as a fuel for polyelectrolyte membrane (PEM) fuel cells. Each reaction in the fuel-processing sequence has a different set of characteristics, which influences the type of catalyst support that should be used for that particular reaction. A wide range of supports are being evaluated for the various reactions in the fuel-processing scheme, including porous and non-porous particles, ceramic and metal straight-channel monoliths, and ceramic and metal monolithic foams. These different types of support have distinctly different transport characteristics. The best choice of support for a given reaction will depend on the design constraints for the system, e.g., allowable pressure drop, and on the characteristics of the reaction for which the catalyst is being designed. Three of the most important reaction characteristics are the intrinsic reaction rate, the exothermicity/endothermicity of the reaction, and the nature of the reaction network, e.g., whether more than one reaction takes place and, in the case of multiple reactions, the configuration of the network. Isotopic transient kinetic analysis was used to study the surface intermediates. The preferential oxidation of low concentrations of carbon monoxide in the presence of high concentrations of hydrogen (PROX) is an important final step in most fuel processor designs. Data on the behavior of straight-channel monoliths and foam monolith supports will be presented to illustrate some of the factors involved in choosing a support for this reaction.

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

    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: Alternative1 First Use of Energy for All Purposes (Fuel and Nonfuel), 2002; Level: National5Sales for4,645 3,625 1,006 492 742Energy ChinaofSchaefer To:Department ofOralGovernmentStandards forand Opportunities for the Metal

  19. Advanced Pattern Material for Investment Casting Applications

    SciTech Connect (OSTI)

    F. Douglas Neece Neil Chaudhry

    2006-02-08T23:59:59.000Z

    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.

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

    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 DataDepartment of Energy Your Density Isn't YourTransport(Fact Sheet), GeothermalGridHYDROGENDDepartmentSeptember 20092009casting Industry |

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

    SciTech Connect (OSTI)

    Dr. Von L. Richards

    2011-09-30T23:59:59.000Z

    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.

  2. A survey of foundries that cast red brass products to ascertain an effective pouring rate of molten metal

    E-Print Network [OSTI]

    Tom, Ronald Kee

    1974-01-01T23:59:59.000Z

    A SURVEY OF FOUNDRIES THAT CAST RED BRASS PRODUCTS TO ASCERTAIN AN EFPECTIVE POURING RATE OF MOLTEN METAL A Thesis by RONALD KEE TOM Submitted to the Graduate College of Texas A&M University in partial fulfillment of the requirement... for the degree of MASTER OF SCIENCE May 1974 Major Subject: Industrial Technology A SURVEY OF FOUNDRIES THAT CAST RED BRASS PRODUCTS TO ASCERTAIN AN EFFECTIVE POURING RATE OF MOLTEN METAL A Thesis by RONALD KEE TOM Approved as to style and content by...

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

    E-Print Network [OSTI]

    2006-01-01T23:59:59.000Z

    silicon (mc-Si) ingot casting for cost-effective solar cell wafer production. Highly sensitive to reduce metal contamination levels in mc-Si solar cells. In this manuscript, we assess the contamination-mail address: istratov@berkeley.edu (A.A. Istratov). #12;over 50% of solar cells worldwide). This source

  4. 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

    2012-06-29T23:59:59.000Z

    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.

  5. 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)

    2003-02-11T23:59:59.000Z

    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).

  6. 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)

    1999-01-01T23:59:59.000Z

    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.

  7. Capacitor with a composite carbon foam electrode

    DOE Patents [OSTI]

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

    1999-04-27T23:59:59.000Z

    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.

  8. 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)

    2001-01-01T23:59:59.000Z

    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.

  9. Panelized wall system with foam core insulation

    DOE Patents [OSTI]

    Kosny, Jan (Oak Ridge, TN); Gaskin, Sally (Houston, TX)

    2009-10-20T23:59:59.000Z

    A wall system includes a plurality of wall members, the wall members having a first metal panel, a second metal panel, and an insulating core between the first panel and the second panel. At least one of the first panel and the second panel include ridge portions. The insulating core can be a foam, such as a polyurethane foam. The foam can include at least one opacifier to improve the k-factor of the foam.

  10. 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]

    BiÁer, Katherine K. (Katherine Kershen)

    2005-01-01T23:59:59.000Z

    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 ...

  11. Preparation of Mesoporous Silica Templated Metal Nanowire Films on Foamed Nickel Substrates

    SciTech Connect (OSTI)

    Campbell, Roger [University of Alabama, Tuscaloosa; Kenik, Edward A [ORNL; Bakker, Martin [University of Alabama, Tuscaloosa; Havrilla, George [Los Alamos National Laboratory (LANL); Montoya, Velma [Los Alamos National Laboratory (LANL); Shamsuzzoha, Mohammed [University of Alabama, Tuscaloosa

    2006-01-01T23:59:59.000Z

    A method has been developed for the formation of high surface area nanowire films on planar and three-dimensional metal electrodes. These nanowire films are formed via electrodeposition into a mesoporous silica film. The mesoporous silica films are formed by a sol-gel process using Pluronic tri-block copolymers to template mesopore formation on both planar and three-dimensional metal electrodes. Surface area increases of up to 120-fold have been observed in electrodes containing a templated film when compared to the same types of electrodes without the templated film.

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

    E-Print Network [OSTI]

    Zabaras, Nicholas J.

    OF THE SOLIDIFICATION OF ALUMINUM ALLOYS ON MOLDS OF UNEVEN TOPOGRAPHIES. Nicholas Zabaras1 , Deep Samanta1 , Lijian Tan of Mechanical and Aerospace Engineering, Cornell University; Ithaca, NY 14853-3801, USA Keywords: Solidification, Aluminum alloys, Cast surfaces, Mold topography, Inverse segregation, Imperfect contact, Air-gaps, Solid

  13. FATIGUE FAILURE OF AN OPEN CELL AND A CLOSED CELL ALUMINIUM ALLOY FOAM

    E-Print Network [OSTI]

    Fleck, Norman A.

    FATIGUE FAILURE OF AN OPEN CELL AND A CLOSED CELL ALUMINIUM ALLOY FOAM A.-M. HARTE, N. A. FLECK reserved. Keywords: Aluminium alloys; Foams; Fatigue; Plastic collapse 1. INTRODUCTION Metallic foams such as aluminium alloy foams show potential for use in ultra-lightweight metallic structures. Recently, a number

  14. ITP Metal Casting: Theoretical/Best Practice Energy Use in Metalcasting

    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 DataDepartment of Energy Your Density Isn't YourTransport(Fact Sheet), GeothermalGridHYDROGENDDepartmentSeptember 20092009castingOperations

  15. Foam patterns

    DOE Patents [OSTI]

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

    2013-11-26T23:59:59.000Z

    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.

  16. A National Assistance Extension Program for Metal Casting: a foundation industry. Final report for the period February 16, 1994 through May 15, 1997

    SciTech Connect (OSTI)

    NONE

    1997-09-01T23:59:59.000Z

    The TRP award was proposed as an umbrella project to build infrastructure and extract lessons about providing extension-enabling services to the metal casting industry through the national network of Manufacturing Technology Center`s (MTC`s). It targeted four discrete task areas required for the MCC to service the contemplated needs of industry, and in which the MCC had secured substantial involvement of partner organizations. Task areas identified included Counter-Gravitational Casting, Synchronous Manufacturing, Technology Deployment, and Facility and Laboratory Improvements. Each of the task areas includes specific subtasks which are described.

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

    E-Print Network [OSTI]

    Kothari, Mitul Arvind

    2005-11-01T23:59:59.000Z

    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...

  18. Foam Micromechanics

    SciTech Connect (OSTI)

    Kraynik, A.M.; Neilsen, M.K.; Reinelt, D.A.; Warren, W.E.

    1998-11-03T23:59:59.000Z

    Foam evokes many different images: waves breaking at the seashore, the head on a pint of Guinness, an elegant dessert, shaving, the comfortable cushion on which you may be seated... From the mundane to the high tech, foams, emulsions, and cellular solids encompass a broad range of materials and applications. Soap suds, mayonnaise, and foamed polymers provide practical motivation and only hint at the variety of materials at issue. Typical of mukiphase materiaIs, the rheoIogy or mechanical behavior of foams is more complicated than that of the constituent phases alone, which may be gas, liquid, or solid. For example, a soap froth exhibits a static shear modulus-a hallmark of an elastic solid-even though it is composed primarily of two Newtonian fluids (water and air), which have no shear modulus. This apparent paradox is easily resolved. Soap froth contains a small amount of surfactant that stabilizes the delicate network of thin liq- uid films against rupture. The soap-film network deforms in response to a macroscopic strain; this increases interracial area and the corresponding sur- face energy, and provides the strain energy of classical elasticity theory [1]. This physical mechanism is easily imagined but very challenging to quantify for a realistic three-dimensional soap froth in view of its complex geome- try. Foam micromechanics addresses the connection between constituent properties, cell-level structure, and macroscopic mechanical behavior. This article is a survey of micromechanics applied to gas-liquid foams, liquid-liquid emulsions, and cellular solids. We will focus on static response where the foam deformation is very slow and rate-dependent phenomena such as viscous flow can be neglected. This includes nonlinear elasticity when deformations are large but reversible. We will also discuss elastic- plastic behavior, which involves yield phenomena. Foam structures based on polyhedra packed to fill space provide a unify- ing geometrical theme. Because a two-dimensional situation is always easier to visualize and usually easier to analyze, the roots of foam micromechanics lie in the plane packed with polygons. There are striking similarities as well as obvious differences between 2D and 3D.

  19. 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 Ultra Large Castings for Lightweight...

  20. Foam Transport in Porous Media - A Review

    SciTech Connect (OSTI)

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

    2009-11-11T23:59:59.000Z

    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 Energyís 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 Ė 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 Ė 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 Darcyís 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).

  1. Liquid foams of graphene

    E-Print Network [OSTI]

    Alcazar Jorba, Daniel

    2012-01-01T23:59:59.000Z

    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, ...

  2. Low density inorganic foams fabricated using microwaves

    SciTech Connect (OSTI)

    Meek, T.T.; Blake, R.D.; Gregory, T.G.

    1985-01-01T23:59:59.000Z

    The objective of our work was to determine if high temperature foams could be made using microwave heating; and if so, to investigate some of their properties. Several foams were made and their compressive strengths, tensile strengths and densities were determined. Foams were made of glass, metal-glass, glass-fiber, metal-glass-fiber, and fly ash. The microwave source used was a Litton model 1521 microwave oven which operated at 2.45 GHz and had an output of 700 watts.

  3. Development of Steel Foam Materials and Structures

    SciTech Connect (OSTI)

    Kenneth Kremer; Anthony Liszkiewicz; James Adkins

    2004-10-20T23:59:59.000Z

    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.

  4. 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

    2011-01-01T23:59:59.000Z

    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,

  5. INDENTATION RESISTANCE OF AN ALUMINIUM FOAM O.B. Olurin, N.A. Fleck

    E-Print Network [OSTI]

    Fleck, Norman A.

    , of relative density 8≠15% were tested. Alporas is a closed cell aluminium alloy foam, consisting of 0.4≠2 wt completed: the cell walls contain the oxides CaO and CaAl2O4. It is a cast aluminium alloy foam and detailsINDENTATION RESISTANCE OF AN ALUMINIUM FOAM O.B. Olurin, N.A. Fleck and M.F. Ashby Cambridge

  6. Heat transfer at the mold-metal interface in permanent mold casting of aluminum alloys project. Quarterly project status report, October 1--December 31, 1998

    SciTech Connect (OSTI)

    Pehlke, R.D.; Hao, S.W.

    1998-12-31T23:59:59.000Z

    The first series of experiments at the CMI-Tech Center was successfully conducted on October 14 and 15 with the participation of the University of Michigan team. The preliminary experimental results indicate that the die surface temperatures (or near the surface) have a close correlation with the metal pressure profiles. Considering the difference in timing of the peak die temperatures, the high melt temperature and hotter die temperature for Inter 54 might cause a longer solidification time, and the pressure would decrease more slowly than for Inter 12. The slopes of the metal pressure profiles at the low pressure setting are almost linear. This may mean that the low metal pressure couldn`t effectively keep a pressure channel opened. In other words, as temperature decreased, the solid fraction increased and the solidified shell strengthened, and the pressure, which couldn`t overcome the resistance, would drop linearly. However, at the high pressure, there are inflection points in the pressure profiles. The inflection points are at about 8,500 psi for both the low and the high melt temperature settings. This suggests that the metal pressure was sufficient enough to overcome the resistance of the solidified shell before the inflection point was reached. A preliminary microstructure analysis shows that the dendrite arms at the location near the gate are much coarser than that at the top of the casting. The influence of intensification pressure on microstructure needs further verification and study.

  7. Coated foams, preparation, uses and articles

    DOE Patents [OSTI]

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

    1982-10-21T23:59:59.000Z

    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.

  8. 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.

    1994-10-25T23:59:59.000Z

    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.

  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)

    1994-01-01T23:59:59.000Z

    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. Foam process models.

    SciTech Connect (OSTI)

    Moffat, Harry K.; Noble, David R.; Baer, Thomas A. (Procter & Gamble Co., West Chester, OH); Adolf, Douglas Brian; Rao, Rekha Ranjana; Mondy, Lisa Ann

    2008-09-01T23:59:59.000Z

    In this report, we summarize our work on developing a production level foam processing computational model suitable for predicting the self-expansion of foam in complex geometries. The model is based on a finite element representation of the equations of motion, with the movement of the free surface represented using the level set method, and has been implemented in SIERRA/ARIA. An empirically based time- and temperature-dependent density model is used to encapsulate the complex physics of foam nucleation and growth in a numerically tractable model. The change in density with time is at the heart of the foam self-expansion as it creates the motion of the foam. This continuum-level model uses an homogenized description of foam, which does not include the gas explicitly. Results from the model are compared to temperature-instrumented flow visualization experiments giving the location of the foam front as a function of time for our EFAR model system.

  11. The industrial ecology of the iron casting industry

    E-Print Network [OSTI]

    Jones, Alissa J. (Alissa Jean)

    2007-01-01T23:59:59.000Z

    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 ...

  12. Heat transfer at the mold-metal interface in permanent mold casting of aluminum alloys project. Annual project status report for the period October 1, 1997 to September 30, 1998

    SciTech Connect (OSTI)

    Pehlke, R.D.; Hao, S.W.

    1998-09-30T23:59:59.000Z

    In the first year of this three-year project, substantial progress has been achieved. This project on heat transfer coefficients in metal permanent mold casting is being conducted in three areas. They are the theoretical study at the University of Michigan, the experimental investigations of squeeze casting and semi-solid casting at CMI-Tech Center, and the experimental investigation of low pressure permanent mold casting at Amcast Automotive. U-M did an initial geometry which was defined for ProCAST to solve, and then a geometry half the size was defined and solved using the same boundary conditions. A conceptual mold geometry was examined and is represented as an axisymmetric element.Furthermore, the influences of the localized heat transfer coefficients on the casting process were carefully studied. The HTC Evaluator has been proposed and initially developed by the U-M team. The Reference and the Database Modules of the HTC Evaluator have been developed, and extensively tested. A series of technical barriers have been cited and potential solutions have been surveyed. At the CMI-Tech Center, the Kistler direct cavity pressure measurement system has been purchased and tested. The calibrations has been evaluated. The probe is capable of sensing a light finger pressure. The experimental mold has been designed and modified. The experimental mold has been designed and modified. The first experiment is scheduled for October 14, 1998. The geometry of the experimental hockey-puck casting has been given to the U-M team for numerical analysis.

  13. High performance polymeric foams

    SciTech Connect (OSTI)

    Gargiulo, M.; Sorrentino, L. [Institute for Composite and Biomedical Materials (IMCB)-CNR, P.le Tecchio 80, 80125 Naples (Italy); Iannace, S. [Institute for Composite and Biomedical Materials (IMCB)-CNR, P.le Tecchio 80, 80125 Naples (Italy) and Technological District on Polymeric and Composite Materials Engineering and Structures (IMAST), P.le E.Fermi 1, location Porto del Granatello, 80055 Portici (Naples)

    2008-08-28T23:59:59.000Z

    The aim of this work was to investigate the foamability of high-performance polymers (polyethersulfone, polyphenylsulfone, polyetherimide and polyethylenenaphtalate). Two different methods have been used to prepare the foam samples: high temperature expansion and two-stage batch process. The effects of processing parameters (saturation time and pressure, foaming temperature) on the densities and microcellular structures of these foams were analyzed by using scanning electron microscopy.

  14. TOUGHNESS OF ALUMINIUM ALLOY FOAMS K. Y. G. McCULLOUGH, N. A. FLECK and M. F. ASHBY{

    E-Print Network [OSTI]

    Fleck, Norman A.

    TOUGHNESS OF ALUMINIUM ALLOY FOAMS K. Y. G. McCULLOUGH, N. A. FLECK and M. F. ASHBY{ Cambridge Science Ltd. All rights reserved. Keywords: Foams; Aluminium alloys; Fracture toughness; Crack growth 1 of metallic foams made from aluminium alloys, with attractive properties for energy management [5, 6], thermal

  15. Casting methods

    DOE Patents [OSTI]

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

    2012-12-18T23:59:59.000Z

    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.

  16. Electrically conductive rigid polyurethane foam

    DOE Patents [OSTI]

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

    1983-12-08T23:59:59.000Z

    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. Electrically conductive rigid polyurethane foam

    DOE Patents [OSTI]

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

    1985-03-19T23:59:59.000Z

    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.

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

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

    recycling of engineered scrap, which preserves metal value. Applications in Our Nation's Industry This project will utilize an automotive door inner as the example casting, but...

  19. Electron beam melting and casting of zirconium and titanium alloys

    SciTech Connect (OSTI)

    Arzhakova, V.M.; Popov, E.I. [A.A. Bochvar All Union Scientific and Research Institute of Inorganic Materials, Moscow (Russian Federation); Dubrovski, V.A.; Frolov, V.I. [PO ChMZ, Glazov (Russian Federation); Ladohin, S.V.; Levitsky, N.I.; Chernyavsky, V.B. [Scientific and Research Institute of Casting, Kiev (Ukraine)

    1994-12-31T23:59:59.000Z

    The results of electron beam melting (EBM) and casting Zirconium and Titanium alloys are discussed. The data on different schedules used for EBM of this metals as well as equipment for crucible melting and special equipment for casting are described. The results of production of Zirconium and Titanium alloy mold castings for various purposes are presented.

  20. 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)

    1987-01-01T23:59:59.000Z

    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.

  1. 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.

    1985-10-02T23:59:59.000Z

    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.

  2. Foam encapsulated targets

    DOE Patents [OSTI]

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

    1983-01-01T23:59:59.000Z

    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. 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)

    1995-01-01T23:59:59.000Z

    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.

  4. Method of preparation of removable syntactic foam

    DOE Patents [OSTI]

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

    1995-07-11T23:59:59.000Z

    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.

  5. Rigid zeolite containing polyurethane foams

    DOE Patents [OSTI]

    Frost, C.B.

    1984-05-18T23:59:59.000Z

    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.

  6. Rigid zeolite containing polyurethane foams

    DOE Patents [OSTI]

    Frost, Charles B. (Livermore, CA)

    1985-01-01T23:59:59.000Z

    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.

  7. Heat transfer at the mold-metal interface in permanent mold casting of aluminum alloys project. Quarterly project status report, April 1--June 30, 1998

    SciTech Connect (OSTI)

    Pehlke, R.D.; Hao, S.W.

    1998-06-30T23:59:59.000Z

    Extensive progress in development of an HTC (heat transfer coefficient) Evaluator and in the preparation of the experiments at CMI and Amcast have been achieved in the last three months. The interface of the HTC Evaluator has been developed in Visual C++ for the PC platform. It provides a tool to collect and store the published data on heat transfer coefficients in a database for further analysis. It also supports the mathematical model for evaluation of heat transfer coefficients. More than 100 papers related to this project have been cited and most of them have been collected. The preparation of the experiments at CMI is almost completed. A hockey-puck mold has been selected for the experiments for squeeze casting and semi-solid casting. A direct cavity pressure measurement system was purchased from Kistler. The pressure probes and data acquisition software as well as the necessary accessories have been delivered. The instrumented mold modification has been designed and the modifications completed. At Amcast Automotive, a new wheel-like mold for low-pressure permanent mold casting was designed. The CAD file for mold fabrication has been generated. The modeling of the casting has been done. An extensive survey on the ultrasonic gap formation measurement was fulfilled. It is concluded that the ultrasonic probe is capable of measuring a gap under the authors` casting conditions. In the last three months, four project meetings has been organized and held with the industrial partners.

  8. Low density microcellular foams

    DOE Patents [OSTI]

    LeMay, James D. (Castro Valley, CA)

    1991-01-01T23:59:59.000Z

    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.

  9. Low density microcellular foams

    DOE Patents [OSTI]

    LeMay, J.D.

    1991-11-19T23:59:59.000Z

    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.

  10. Deformation rate effects on failure modes of open-cell Al foams and textile cellular materials

    E-Print Network [OSTI]

    Barthelat, Francois

    September 2005 Abstract The compressive behavior of open-cell aluminum alloy foam and stainless steel woven: Metallic cellular materials; Dynamic compression; Aluminum foams; Woven textile lattice 0020-7683/$ - see are of attracting interest for a variety of automotive, locomotive, marine, and aerospace applications (Gibson

  11. 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)

    1985-01-01T23:59:59.000Z

    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.

  12. 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)

    2010-12-07T23:59:59.000Z

    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.

  13. Foam Processing of Textiles

    E-Print Network [OSTI]

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

    1984-01-01T23:59:59.000Z

    and half by the foam pro Finish Wet Pick-Up 68.4% 25% cess. A typical lot consists of 10 to 20 thou Calculated Holst.ure on Fabric 67.6 24.4 sand lineal yards. The solids add-on of finish Dryer Temp.op. 345/380 260/265 ing chemicals was the same...

  14. 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 [ORNL; Truhan, Jr., John J [ORNL; Kenik, Edward A [ORNL

    2007-01-01T23:59:59.000Z

    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.

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

    DOE Patents [OSTI]

    Taleyarkhan, Rusi P. (Knoxville, TN)

    1996-01-01T23:59:59.000Z

    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.

  16. Low density microcellular foams

    DOE Patents [OSTI]

    LeMay, James D. (Castro Valley, CA)

    1992-01-01T23:59:59.000Z

    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.

  17. High temperature lightweight foamed cements

    DOE Patents [OSTI]

    Sugama, Toshifumi (Mastic Beach, NY)

    1989-01-01T23:59:59.000Z

    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.

  18. High temperature lightweight foamed cements

    DOE Patents [OSTI]

    Sugama, Toshifumi.

    1989-10-03T23:59:59.000Z

    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.

  19. Understanding the Role Water-cooling Plays during Continuous Casting of Steel and Aluminum Alloys

    E-Print Network [OSTI]

    Thomas, Brian G.

    Understanding the Role Water-cooling Plays during Continuous Casting of Steel and Aluminum Alloys J the mold and solidifying metal during the continuous casting of steel and aluminum alloys for the control of cooling in casting processes for both steel and aluminum alloys are evaluated. Introduction

  20. The Current State of Casting Yield: Results from the 1997 Steel Founders'

    E-Print Network [OSTI]

    Beckermann, Christoph

    , Chicago, IL, 1997. #12;lNTRODUCTlON It is commonly believed that the average metal yield in the steel casting industry is approximately 50 to 55 percent. A primary goal of conducting the casting yield survey additional costs in remelting scrapped steel (estimated to account for 7% of the total casting cost

  1. Heat transfer at the mold-metal interface in permanent mold casting of aluminum alloys project. Quarterly project status report, January 1, 1998--March 31, 1998

    SciTech Connect (OSTI)

    Pehlke, R.D.; Hao, Shouwei; Cookson, J.M.

    1998-03-31T23:59:59.000Z

    There have been numerous developments in the current project over the last three months. The most appropriate geometries for performing the interfacial heat transfer studies have been discussed with both of our Industrial Partners. Both companies have molds which may be available for adaptation to record the thermal history during casting required for determining interfacial heat transfer coefficients. The details of what instrumentation would be the most appropriate remain to be worked out, but the instrumentation would likely include thermocoupling in the mold cavity as well as in the mold wall, as well as pressure sensors in the squeeze casting geometry molds and ultrasonic gap monitoring in the low pressure and gravity fed permanent mold geometry molds. The first advisory committee meeting was held on February 6th, and the steering committee was apprised of the objectives of the program. The capabilities of the Industrial Partners were reviewed, as well as the need for the project to make use of resources from other CMC projects. The second full Advisory Committee Meeting will be held in early May.

  2. Process and apparatus for casting multiple silicon wafer articles

    DOE Patents [OSTI]

    Nanis, Leonard (Palo Alto, CA)

    1992-05-05T23:59:59.000Z

    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.

  3. Spherical Foams in Flat Space

    E-Print Network [OSTI]

    Carl D. Modes; Randall D. Kamien

    2008-10-31T23:59:59.000Z

    Regular tesselations of space are characterized through their Schlafli symbols {p,q,r}, where each cell has regular p-gonal sides, q meeting at each vertex, and r meeting on each edge. Regular tesselations with symbols {p,3,3} all satisfy Plateau's laws for equilibrium foams. For general p, however, these regular tesselations do not embed in Euclidean space, but require a uniform background curvature. We study a class of regular foams on S^3 which, through conformal, stereographic projection to R^3 define irregular cells consistent with Plateau's laws. We analytically characterize a broad classes of bulk foam bubbles, and extend and explain recent observations on foam structure and shape distribution. Our approach also allows us to comment on foam stability by identifying a weak local maximum of A^(3/2)/V at the maximally symmetric tetrahedral bubble that participates in T2 rearrangements.

  4. Mechanical Characterization of Rigid Polyurethane Foams.

    SciTech Connect (OSTI)

    Lu, Wei-Yang

    2014-12-01T23:59:59.000Z

    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.

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

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

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

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

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

    Casting Evaluation for High Volume Structural Castings 2012 DOE Hydrogen and Fuel Cells Program and Vehicle Technologies Program Annual Merit Review and Peer Evaluation...

  7. Carbon foam characterization tensile evaluation of carbon foam ligaments†

    E-Print Network [OSTI]

    Verdugo Rodriguez, Rogelio Alberto

    2004-09-30T23:59:59.000Z

    A methodology for ligament isolation and specimen preparation for tensile testing of single ligaments from the unit cell of open-cell carbon foams has been successfully developed and implemented. Results are presented for ...

  8. Carbon foam characterization tensile evaluation of carbon foam ligaments

    E-Print Network [OSTI]

    Verdugo Rodriguez, Rogelio Alberto

    2004-09-30T23:59:59.000Z

    foam microstructure 100 Ķ 6 In this procedure, Crystalbond? is used which is a commercially available wax for temporarily mounting of materials that require dicing, polishing, and other machining processes. When processing is complete, this wax...

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

    SciTech Connect (OSTI)

    Fleming, W.H. Jr.

    1999-10-20T23:59:59.000Z

    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.

  10. Supercapacitors based on carbon foams

    DOE Patents [OSTI]

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

    1993-11-09T23:59:59.000Z

    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.

  11. 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)

    1993-01-01T23:59:59.000Z

    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.

  12. 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)

    2014-07-21T23:59:59.000Z

    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 0.94Ė1.2?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.

  13. MECHANISTIC STUDIES OF IMPROVED FOAM EOR PROCESSES

    SciTech Connect (OSTI)

    William R. Rossen

    2005-01-05T23:59:59.000Z

    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.

  14. Epoxy Foam Encapsulants: Processing and Dielectric Characterization

    SciTech Connect (OSTI)

    Linda Domeier; Marion Hunter

    1999-01-01T23:59:59.000Z

    The dielectric performance of epoxy foams was investigated to determine if such materials might provide advantages over more standard polyurethane foams in the encapsulation of electronic assemblies. Comparisons of the dielectric characteristics of epoxy and urethane encapsulant foams found no significant differences between the two resin types and no significant difference between as-molded and machined foams. This study specifically evaluated the formulation and processing of epoxy foams using simple methylhydrosiloxanes as the flowing agent and compared the dielectric performance of those to urethane foams of similar density.

  15. MECHANISTIC STUDIES OF IMPROVED FOAM EOR PROCESSES

    SciTech Connect (OSTI)

    William R. Rossen

    2005-03-16T23:59:59.000Z

    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.

  16. Optimization of Squeeze Casting for Aluminum Alloy Parts

    SciTech Connect (OSTI)

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

    2002-07-30T23:59:59.000Z

    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. 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)

    2014-05-15T23:59:59.000Z

    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)

  18. Method of casting aerogels

    DOE Patents [OSTI]

    Poco, John F. (Livermore, CA)

    1993-01-01T23:59:59.000Z

    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.

    1993-09-07T23:59:59.000Z

    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. 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)

    2002-01-01T23:59:59.000Z

    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.

  1. Buoyancy Effects on Smoldering of Polyurethane Foam

    E-Print Network [OSTI]

    Torero, Jose L

    1992-11-19T23:59:59.000Z

    An experimental study has been carried out to investigate the effects of buoyancy on smoldering of polyurethane foam. The experiments are conducted with a high void fraction flexible polyurethane foam as fuel and air as ...

  2. Determination of foam stability at constant pressure in the Plateau-Biggs borders of the foam

    SciTech Connect (OSTI)

    Khristov, K.I.; Exerowa, D.R.; Kurgljakov, P.M.

    1981-02-01T23:59:59.000Z

    The lifetime of a foam column (or of a part of the column) is a parameter widely used as a characteristic of foam stability. During the destruction process, the pressure in the upper layers of the foam changes (the height H of the foam column decreases) and the lifetime of the different layers of the foam column will be different. Therefore, the lifetime of a foam column at constant pressure in the Plateau-Gibbs borders (constant along the height of the column and with time) is a much more accurate characteristic of foam stability.

  3. Electron beam casting technology in the former Soviet Union

    SciTech Connect (OSTI)

    Ladokhin, S.V. [Inst. of Foundry Problems, Kiev (Ukraine)

    1995-12-31T23:59:59.000Z

    In this report the results of the investigation of metals and alloys melting and casting in the EB skull installations in the former USSR are given. The technological equipment used for these purposes is described. The long term prospects for the technological and engineering developments for multicomponent alloy melting and casting, including those containing volatile elements are shown. The significant technological advantages of the electro-magnetic stirring used in the course of the EB melting are demonstrated. The important advantage of the technology described is the efficient processing of metals and alloys metals.

  4. Engineering the Quantum Foam

    E-Print Network [OSTI]

    Reginald T. Cahill

    2005-06-06T23:59:59.000Z

    In 1990 Alcubierre, within the General Relativity model for space-time, proposed a scenario for `warp drive' faster than light travel, in which objects would achieve such speeds by actually being stationary within a bubble of space which itself was moving through space, the idea being that the speed of the bubble was not itself limited by the speed of light. However that scenario required exotic matter to stabilise the boundary of the bubble. Here that proposal is re-examined within the context of the new modelling of space in which space is a quantum system, viz a quantum foam, with on-going classicalisation. This model has lead to the resolution of a number of longstanding problems, including a dynamical explanation for the so-called `dark matter' effect. It has also given the first evidence of quantum gravity effects, as experimental data has shown that a new dimensionless constant characterising the self-interaction of space is the fine structure constant. The studies here begin the task of examining to what extent the new spatial self-interaction dynamics can play a role in stabilising the boundary without exotic matter, and whether the boundary stabilisation dynamics can be engineered; this would amount to quantum gravity engineering.

  5. Method for making thin carbon foam electrodes

    DOE Patents [OSTI]

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

    1999-08-03T23:59:59.000Z

    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.

  6. Pipe viscometry of foams C. Enzendorfer

    E-Print Network [OSTI]

    Valkó, Peter

    of foams is usually characterized by the quality, r, defined as the ratio of the gas volume to the total,and quality was determined in pipes of five diameters. The flow curves showed a marked dependenceon foam volume. High-quality foams, above 93%-97% have the tendency to invert into mist. In a mist

  7. Foam vessel for cryogenic fluid storage

    DOE Patents [OSTI]

    Spear, Jonathan D (San Francisco, CA)

    2011-07-05T23:59:59.000Z

    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.

  8. Highly concentrated foam formulation for blast mitigation

    DOE Patents [OSTI]

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

    2010-12-14T23:59:59.000Z

    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.

  9. UNIAXIAL STRESSSTRAIN BEHAVIOUR OF ALUMINIUM ALLOY FOAMS

    E-Print Network [OSTI]

    Fleck, Norman A.

    UNIAXIAL STRESSĪSTRAIN BEHAVIOUR OF ALUMINIUM ALLOY FOAMS K.Y.G. McCULLOUGH, N.A. FLECK and M of closed cell aluminium alloy foams (trade name ``Alulight'') has been measured and interpreted in terms. All rights reserved. Keywords: Aluminium alloys; Foams; Deformation mechanisms 1. INTRODUCTION Recent

  10. Application of statistical methods for analyzing the relationship between casting distortion, mold filling, and interfacial heat transfer in sand molds

    SciTech Connect (OSTI)

    Y. A. Owusu

    1999-03-31T23:59:59.000Z

    This report presents a statistical method of evaluating geometric tolerances of casting products using point cloud data generated by coordinate measuring machine (CMM) process. The focus of this report is to present a statistical-based approach to evaluate the differences in dimensional and form variations or tolerances of casting products as affected by casting gating system, molding material, casting thickness, and casting orientation at the mold-metal interface. Form parameters such as flatness, parallelism, and other geometric profiles such as angularity, casting length, and height of casting products were obtained and analyzed from CMM point cloud data. In order to relate the dimensional and form errors to the factors under consideration such as flatness and parallelism, a factorial analysis of variance and statistical test means methods were performed to identify the factors that contributed to the casting distortion at the mold-metal interface.

  11. 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)

    1985-01-01T23:59:59.000Z

    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.

  12. Process for epoxy foam production

    DOE Patents [OSTI]

    Celina, Mathias C. (Albuquerque, NM)

    2011-08-23T23:59:59.000Z

    An epoxy resin mixture with at least one epoxy resin of between approximately 60 wt % and 90 wt %, a maleic anhydride of between approximately 1 wt % and approximately 30 wt %, and an imidazole catalyst of less than approximately 2 wt % where the resin mixture is formed from at least one epoxy resin with a 1-30 wt % maleic anhydride compound and an imidazole catalyst at a temperature sufficient to keep the maleic anhydride compound molten, the resin mixture reacting to form a foaming resin which can then be cured at a temperature greater than 50.degree. C. to form an epoxy foam.

  13. Heat exchanger using graphite foam

    DOE Patents [OSTI]

    Campagna, Michael Joseph; Callas, James John

    2012-09-25T23:59:59.000Z

    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.

  14. Spacetime Foam and Dark Energy

    E-Print Network [OSTI]

    Y. Jack Ng

    2008-08-08T23:59:59.000Z

    Due to quantum fluctuations, spacetime is foamy on small scales. The degree of foaminess is found to be consistent with the holographic principle. One way to detect spacetime foam is to look for halos in the images of distant quasars. Applying the holographic foam model to cosmology we "predict" that the cosmic energy density takes on the critical value; and basing only on existing archived data on active galactic nuclei from the Hubble Space Telescope, we also "predict" the existence of dark energy which, we argue, is composed of an enormous number of inert "particles" of extremely long wavelength. We speculate that these "particles" obey infinite statistics.

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

    DOE Patents [OSTI]

    Young, A.T.

    1982-03-03T23:59:59.000Z

    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.

  16. 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)

    1984-01-01T23:59:59.000Z

    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.

  17. Method of making a cyanate ester foam

    DOE Patents [OSTI]

    Celina, Mathias C.; Giron, Nicholas Henry

    2014-08-05T23:59:59.000Z

    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.

  18. 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.

    2007-01-02T23:59:59.000Z

    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.

  19. 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)

    1990-02-20T23:59:59.000Z

    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.

  20. 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 [Korea Atomic Energy Research Institute, Daedeok-daro 989-111, Yuseong-gu, Daejeon (Korea, Republic of)

    2013-07-01T23:59:59.000Z

    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.

  1. STANDING WAVE PROBES FOR DIMENSIONAL METROLOGY OF LOW DENSITY FOAMS

    SciTech Connect (OSTI)

    Seugling, R M; Woody, S C; Bauza, M B

    2010-03-23T23:59:59.000Z

    Typically, parts and geometries of interest to LLNL are made from a combination of complex geometries and a wide array of different materials ranging from metals and ceramics to low density foams and plastic foils. These parts are combined to develop physics experiments for studying material properties, equation of state (EOS) and radiation transport. Understanding the dimensional uncertainty of the parts contained within an experiment is critical to the physical understanding of the phenomena being observed and represents the motivation for developing probe metrology capability that can address LLNL's unique problems. Standing wave probes were developed for measuring high aspect ratio, micrometer scaled features with nanometer resolution. Originally conceived of for the use in the automotive industry for characterizing fuel injector bores and similar geometries, this concept was investigated and improved for use on geometries and materials important to LLNL needs within target fabrication. As part of the original project, detailed understanding of the probe dynamics and interactions with the surface of the sample was investigated. In addition, the upgraded system was utilized for measuring fuel injector bores and micro-lenses as a means of demonstrating capability. This report discusses the use of the standing wave probe for measuring features in low density foams, 55 mg/cc SiO{sub 2} and 982 mg/cc (%6 relative density) copper foam respectively. These two foam materials represent a difficult metrology challenge because of their material properties and surface topography. Traditional non-contact metrology systems such as normal incident interferometry and/or confocal microscopy have difficulty obtaining a signal from the relatively absorptive characteristics of these materials. In addition to the foam samples, a solid copper and plastic (Rexolite{trademark}) sample of similar geometry was measured with the standing wave probe as a reference for both conductive and dielectric materials.

  2. Electromagnetic continuous casting project: Final report

    SciTech Connect (OSTI)

    Battles, J.E.; Rote, D.M.; Misra, B.; Praeg, W.F.; Hull, J.R.; Turner, L.R.; Shah, V.L.; Lari, R.J.; Gopalsami, N.; Wiencek, T.

    1988-10-01T23:59:59.000Z

    This report describes the work on development of an electromagnetic casting process for steel, which was carried out at Argonne National Laboratory between January 1985 and December 1987. This effort was concerned principally with analysis and design work on magnet technology, liquid metal feed system, coolant system, and sensors and process controllers. Experimentation primarily involved (1) electromagnetic studies to determine the conditions and controlling parameters for stable levitation and (2) feed-system studies to establish important parameters that control and influence fluid flow from the liquid metal source to the caster. 73 refs., 91 figs., 11 tabs.

  3. Extrusion cast explosive

    DOE Patents [OSTI]

    Scribner, Kenneth J. (Livermore, CA)

    1985-01-01T23:59:59.000Z

    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.

  4. Antioxidant behavior in flexible PU foam

    SciTech Connect (OSTI)

    Skorpenske, R.G.; Schrock, A.K.

    1991-09-01T23:59:59.000Z

    In this article, data are given regarding the AO concentration profiles across foam buns as a function of the corresponding temperature profile of the foams studied, three were produced on a Varimax pilot line located at Dow Chemical Company Freeport, Texas. The fourth foam used for this study was a production scale foam made at Texas Fibers, a Division of Leggett and Platt, Brenham, Texas. The foams produced on the Varimas include formulations using 4.1, 5.1 and 6.1 parts per hundred parts (pphp) water based on polyol and can be compared to the 4.1 pphp water foam made at Texas Fibers. Temperature data, collected from a foam-in-place grid of thermocouples, gives the time-temperature profile within the foam bun as a function of location. Foam samples which have been removed from locations corresponding to the thermocouples are examined, via methylene chloride extraction and liquid chromatographic analysis, for antioxidant content. The objective is to determine the significance of the foam environment, as a function of formulation, on the behavior of antioxidants.

  5. Tailor Blank Casting - Control of sheet width using an electromagnetic edge dam in aluminium twin roll casting

    E-Print Network [OSTI]

    McBrien, Martin; Allwood, Julian M.; Barekar, Nilam S.

    2015-04-01T23:59:59.000Z

    stock products such as coils of the manufacturing industries which take these stock d reshape them to make consumer products, for exam- rs. This makes the supply chain subtractiveóa large the metal cast is removed and does not reach the final roduct... , as bor casting tria For the c zero, a hori P m h + 2#3; si Using th plays an im metal conta separation as the solid sion in the dge dam (EMED); (b) longitudinal view, centreline of strip, EMED on; w, EMED on, far edge. the biggest challenge...

  6. Effect of furnace atmosphere on E-glass foaming

    E-Print Network [OSTI]

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

    2006-01-01T23:59:59.000Z

    oxy-fired furnaces. E-glass foams were generated in a fused-81.05.K 1. Introduction Glass foams generated in glass-that the stability of E-glass foam decreased with increasing

  7. Activated, coal-based carbon foam

    DOE Patents [OSTI]

    Rogers, Darren Kenneth; Plucinski, Janusz Wladyslaw

    2004-12-21T23:59:59.000Z

    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.

  8. Blast mitigation capabilities of aqueous foam.

    SciTech Connect (OSTI)

    Hartman, William Franklin; Larsen, Marvin Elwood; Boughton, Bruce A.

    2006-02-01T23:59:59.000Z

    A series of tests involving detonation of high explosive blanketed by aqueous foam (conducted from 1982 to 1984) are described in primarily terms of recorded peak pressure, positive phase specific impulse, and time of arrival. The investigation showed that optimal blast mitigation occurs for foams with an expansion ratio of about 60:1. Simple analyses representing the foam as a shocked single phase mixture are presented and shown inadequate. The experimental data demonstrate that foam slows down and broadens the propagated pressure disturbance relative to a shock in air. Shaped charges and flyer plates were evaluated for operation in foam and appreciable degradation was observed for the flyer plates due to drag created by the foam.

  9. Experimental and Numerical Investigation of Forging Process to Reproduce a 3D Aluminium Foam Complex Shape

    SciTech Connect (OSTI)

    Filice, Luigino; Gagliardi, Francesco; Umbrello, Domenico [Department of Mechanical Engineering, University of Calabria, P. Bucci, 87036 Rende (Serbia and Montenegro) (Italy); Shivpuri, Rajiv [Department of Industrial, Welding and System Engineering, Ohio State University, 1971 Neil Avenue, 210 Baker Systems, Columbus, OH 43210-1217 (United States)

    2007-05-17T23:59:59.000Z

    Metallic foams represent one of the most exciting materials introduced in the manufacturing scenario in the last years. In the study here addressed, the experimental and numerical investigations on the forging process of a simple foam billet shaped into complex sculptured parts were carried out. In particular, the deformation behavior of metallic foams and the development of density gradients were investigated through a series of experimental forging tests in order to produce a selected portion of a hip prosthesis. The human bone replacement was chosen as case study due to its industrial demand and for its particular 3D complex shape. A finite element code (Deform 3D) was utilized for modeling the foam behavior during the forging process and an accurate material rheology description was used based on a porous material model which includes the measured local density. Once the effectiveness of the utilized Finite Element model was verified through the comparison with the experimental evidences, a numerical study of the influence of the foam density was investigated. The obtained numerical results shown as the initial billet density plays an important role on the prediction of the final shape, the optimization of the flash as well as the estimation of the punch load.

  10. Aqueous foam toxicology evaluation and hazard review

    SciTech Connect (OSTI)

    Archuleta, M.M.

    1995-10-01T23:59:59.000Z

    Aqueous foams are aggregates of bubbles mechanically generated by passing air or other gases through a net, screen, or other porous medium that is wetted by an aqueous solution of surface-active foaming agents (surfactants). Aqueous foams are important in modem fire-fighting technology, as well as for military uses for area denial and riot or crowd control. An aqueous foam is currently being developed and evaluated by Sandia National Laboratories (SNL) as a Less-Than-Lethal Weapon for the National Institute of Justice (NIJ). The purpose of this study is to evaluate the toxicity of the aqueous foam developed for the NIJ and to determine whether there are any significant adverse health effects associated with completely immersing individuals without protective equipment in the foam. The toxicity of the aqueous foam formulation developed for NIJ is determined by evaluating the toxicity of the individual components of the foam. The foam is made from a 2--5% solution of Steol CA-330 surfactant in water generated at expansion ratios ranging from 500:1 to 1000:1. SteoI CA-330 is a 35% ammonium laureth sulfate in water and is produced by Stepan Chemical Company and containing trace amounts (<0.1%) of 1,4-dioxane. The results of this study indicate that Steol CA-330 is a non-toxic, mildly irritating, surfactant that is used extensively in the cosmetics industry for hair care and bath products. Inhalation or dermal exposure to this material in aqueous foam is not expected to produce significant irritation or systemic toxicity to exposed individuals, even after prolonged exposure. The amount of 1,4-dioxane in the surfactant, and subsequently in the foam, is negligible and therefore, the toxicity associated with dioxane exposure is not significant. In general, immersion in similar aqueous foams has not resulted in acute, immediately life-threatening effects, or chronic, long-term, non-reversible effects following exposure.

  11. Process for preparing silicon carbide foam

    DOE Patents [OSTI]

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

    1997-09-16T23:59:59.000Z

    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.

  12. Process for preparing silicon carbide foam

    DOE Patents [OSTI]

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

    1997-01-01T23:59:59.000Z

    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.

  13. 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)

    1999-01-01T23:59:59.000Z

    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.

  14. Alloy Foam Diesel Emissions Control School Bus Implementation...

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

    Alloy Foam Diesel Emissions Control School Bus Implementation Alloy Foam Diesel Emissions Control School Bus Implementation Poster presentation from the 2007 Diesel...

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

    DOE Patents [OSTI]

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

    1999-03-16T23:59:59.000Z

    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.

  16. 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...

  17. abrogating foam cell: Topics by E-print Network

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

    are easily prepared by micro- emulsion templates. These silica foams resemble dense aerogels. Introduction Because of their greatly enhanced pore Yang, Peidong 16 Foams in a...

  18. Extrusion cast explosive

    DOE Patents [OSTI]

    Scribner, K.J.

    1985-11-26T23:59:59.000Z

    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.

  19. Extrusion cast explosive

    DOE Patents [OSTI]

    Scribner, K.J.

    1985-01-29T23:59:59.000Z

    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.

  20. ITP Metal Casting: Metalcasting Industry Technology Roadmap

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

    foundries spend a higher proportion of their funds available for capital improvements on pollution control equipment. The industry as a whole, however, invests significantly in...

  1. 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)

    2009-11-10T23:59:59.000Z

    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.

  2. Damping of liquid sloshing by foams

    E-Print Network [OSTI]

    Alban Sauret; FranÁois Boulogne; Jean Cappello; Emilie Dressaire; Howard A. Stone

    2015-02-01T23:59:59.000Z

    When a container is set in motion, the free surface of the liquid starts to oscillate or slosh. Such effects can be observed when a glass of water is handled carelessly and the fluid sloshes or even spills over the rims of the container. However, beer does not slosh as readily as water, which suggests that foam could be used to damp sloshing. In this work, we study experimentally the effect on sloshing of a liquid foam placed on top of a liquid bath. We generate a monodisperse two-dimensional liquid foam in a rectangular container and track the motion of the foam. The influence of the foam on the sloshing dynamics is experimentally characterized: only a few layers of bubbles are sufficient to significantly damp the oscillations. We rationalize our experimental findings with a model that describes the foam contribution to the damping coefficient through viscous dissipation on the walls of the container. Then we extend our study to confined three-dimensional liquid foam and observe that the behavior of 2D and confined 3D systems are very similar. Thus we conclude that only the bubbles close to the walls have a significant impact on the dissipation of energy. The possibility to damp liquid sloshing using foam is promising in numerous industrial applications such as the transport of liquefied gas in tankers or for propellants in rocket engines.

  3. Directly susceptible, noncarbon metal ceramic composite crucible

    DOE Patents [OSTI]

    Holcombe, Jr., Cressie E. (Farragut, TN); Kiggans, Jr., James O. (Oak Ridge, TN); Morrow, S. Marvin (Kingston, TN); Rexford, Donald (Pattersonville, NY)

    1999-01-01T23:59:59.000Z

    A sintered metal ceramic crucible suitable for high temperature induction melting of reactive metals without appreciable carbon or silicon contamination of the melt. The crucible comprises a cast matrix of a thermally conductive ceramic material; a perforated metal sleeve, which serves as a susceptor for induction heating of the crucible, embedded within the ceramic cast matrix; and a thermal-shock-absorber barrier interposed between the metal sleeve and the ceramic cast matrix to allow for differential thermal expansions between the matrix and the metal sleeve and to act as a thermal-shock-absorber which moderates the effects of rapid changes of sleeve temperature on the matrix.

  4. Seal welded cast iron nuclear waste container

    DOE Patents [OSTI]

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

    1987-01-01T23:59:59.000Z

    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.

  5. Foam generator and viscometer apparatus and process

    DOE Patents [OSTI]

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

    2004-10-26T23:59:59.000Z

    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.

  6. Chemical Engineering and Processing 43 (2004) 149160 Minimum superficial gas velocity for onset of foaming

    E-Print Network [OSTI]

    Pilon, Laurent

    ; Foam fractionation; Slag foaming; Glass foam 1. Introduction Semi-batch foams or pneumatic foams protein concentration [2]. In food processes or in glass melting furnaces, foam is unde- sirable since of foaming Laurent Pilona,, Raymond Viskantab a Mechanical and Aerospace Engineering Department, University

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

    E-Print Network [OSTI]

    Kilpatrick, Peter K.

    to the petroleum industry. Nonaqueous foams occur in the production of and refining of crude oil. Crude oil foamsFactors Contributing to Petroleum Foaming. 2. Synthetic Crude Oil Systems Nael N. Zaki, Michael K August 28, 2001 The influence of petroleum asphaltenes and resins on stabilizing model oil foams

  8. 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.

    1983-12-21T23:59:59.000Z

    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.

  9. Final Report, Volume 1, Metallurgical Evaluation of Cast Duplex Stainless Steels and their Weldments

    SciTech Connect (OSTI)

    Wen, Songqing; Lundin, Carl, W.; Batten, Greg, W.

    2005-09-30T23:59:59.000Z

    Duplex stainless steels (DSS) are being specified for chloride containing environments due to their enhanced pitting and stress corrosion cracking resistance. They exhibit improved corrosion performance over the austenitic stainless steels. Duplex stainless steels also offer improved strength properties and are available in various wrought and cast forms. Selected grades of duplex stainless steel castings and their welds, in comparison with their wrought counterparts, were evaluated, regarding corrosion performance and mechanical properties and weldability. Multiple heats of cast duplex stainless steel were evaluated in the as-cast, solution annealed (SA) static cast and SA centrifugal cast conditions, while their wrought counterparts were characterized in the SA condition and in the form of as-rolled plate. Welding, including extensive assessment of autogenous welds and a preliminary study of composite welds (shielded metal arc weld (SMAW)), was performed. The evaluations included critical pitting temperature (CPT) testing, intergranular corrosion (IGC) testing, ASTM A923 (Methods A, B and C), Charpy impact testing, weldability testing (ASTM A494), ferrite measurement and microstructural evaluations. In the study, the corrosion performances of DSS castings were characterized and assessed, including the wrought counterparts for comparison. The evaluation filled the pore of lack of data for cast duplex stainless steels compared to wrought materials. A database of the pitting corrosion and IGC behavior of cast and wrought materials was generated for a greater depth of understanding for the behavior of cast duplex stainless steel. In addition, improved evaluation methods for DSS castings were developed according to ASTM A923, A262, G48 and A494. The study revealed that when properly heat treated according to the specification, (1) DSS castings have equal or better pitting and intergranular corrosion resistance than their wrought counterparts; (2) Welding reduces the pitting and intergranular corrosion resistance for both the wrought and cast duplex alloys; (3) Castings generally have better toughness than their wrought counterparts in the temperature range of √?¬?√?¬?√?¬?√?¬Ę√?¬?√?¬?√?¬?√?¬?√?¬?√?¬?√?¬?√?¬?80√?¬?√?¬?√?¬?√?¬?√?¬?√?¬?√?¬?√?¬įC to +20√?¬?√?¬?√?¬?√?¬?√?¬?√?¬?√?¬?√?¬įC; (4) All shield metal arc (SMA) test welds in DSS castings, with recommended or over matching filler metal, indicate that welding is not a significant factor when considering DSS applications.

  10. Final Report, Volume 1, Metallurgical Evaluation of Cast Duplex Stainless Steels and their Weldments

    SciTech Connect (OSTI)

    Wen, Songqing; Lundin, Carl, W.; Batten, Greg, W.

    2005-09-30T23:59:59.000Z

    Duplex stainless steels (DSS) are being specified for chloride containing environments due to their enhanced pitting and stress corrosion cracking resistance. They exhibit improved corrosion performance over the austenitic stainless steels. Duplex stainless steels also offer improved strength properties and are available in various wrought and cast forms. Selected grades of duplex stainless steel castings and their welds, in comparison with their wrought counterparts, were evaluated, regarding corrosion performance and mechanical properties and weldability. Multiple heats of cast duplex stainless steel were evaluated in the as-cast, solution annealed (SA) static cast and SA centrifugal cast conditions, while their wrought counterparts were characterized in the SA condition and in the form of as-rolled plate. Welding, including extensive assessment of autogenous welds and a preliminary study of composite welds (shielded metal arc weld (SMAW)), was performed. The evaluations included critical pitting temperature (CPT) testing, intergranular corrosion (IGC) testing, ASTM A923 (Methods A, B and C), Charpy impact testing, weldability testing (ASTM A494), ferrite measurement and microstructural evaluations. In the study, the corrosion performances of DSS castings were characterized and assessed, including the wrought counterparts for comparison. The evaluation filled the pore of lack of data for cast duplex stainless steels compared to wrought materials. A database of the pitting corrosion and IGC behavior of cast and wrought materials was generated for a greater depth of understanding for the behavior of cast duplex stainless steel. In addition, improved evaluation methods for DSS castings were developed according to ASTM A923, A262, G48 and A494. The study revealed that when properly heat treated according to the specification, (1) DSS castings have equal or better pitting and intergranular corrosion resistance than their wrought counterparts; (2) Welding reduces the pitting and intergranular corrosion resistance for both the wrought and cast duplex alloys; (3) Castings generally have better toughness than their wrought counterparts in the temperature range of -80 C to +20 C; (4) All shield metal arc (SMA) test welds in DSS castings, with recommended or over matching filler metal, indicate that welding is not a significant factor when considering DSS applications.

  11. Yield criteria for quasibrittle and frictional materials Davide Bigoni *, Andrea Piccolroaz

    E-Print Network [OSTI]

    Piccolroaz, Andrea

    to soil, concrete, rock, metallic and composite powders, metallic foams, porous metals, and polymers denomination for soil, concrete, rock, granular media, coal, cast iron, ice, porous metals, metallic foams. Keywords: Yield criteria; Elastic­plastic material; Concrete; Foam material; Geological material; Granular

  12. Spin Foam Models from the Tetrad Integration

    E-Print Network [OSTI]

    A. Mikovic

    2005-11-15T23:59:59.000Z

    We describe a class of spin foam models of four-dimensional quantum gravity which is based on the integration of the tetrad one-forms in the path integral for the Palatini action of General Relativity. In the Euclidian gravity case this class of models can be understood as a modification of the Barrett-Crane spin foam model. Fermionic matter can be coupled by using the path integral with sources for the tetrads and the spin connection, and the corresponding state sum is based on a spin foam where both the edges and the faces are colored independently with the irreducible representations of the spacetime rotations group.

  13. 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.)

    1989-01-01T23:59:59.000Z

    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.

  14. Wick for metal vapor laser

    DOE Patents [OSTI]

    Duncan, David B. (Livermore, CA)

    1992-01-01T23:59:59.000Z

    An improved wick for a metal vapor laser is made of a refractory metal cylinder, preferably molybdenum or tungsten for a copper laser, which provides the wicking surface. Alternately, the inside surface of the ceramic laser tube can be metalized to form the wicking surface. Capillary action is enhanced by using wire screen, porous foam metal, or grooved surfaces. Graphite or carbon, in the form of chunks, strips, fibers or particles, is placed on the inside surface of the wick to reduce water, reduce metal oxides and form metal carbides.

  15. Uniformly dense polymeric foam body

    DOE Patents [OSTI]

    Whinnery Jr., Leroy

    2003-07-15T23:59:59.000Z

    A method for providing a uniformly dense polymer foam body having a density between about 0.013 g/cm.sup.3 to about 0.5 g/cm.sup.3 is disclosed. The method utilizes a thermally expandable polymer microsphere material wherein some of the microspheres are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about 130.degree. C., and then cooling the mold to a temperature below 80.degree. C. the molded part achieves a bulk density which varies by less then about .+-.6% everywhere throughout the part volume.

  16. Generalized correlation for foam flow in tubes

    E-Print Network [OSTI]

    Cotter, Carol Lynnette

    1996-01-01T23:59:59.000Z

    . Data collected allow for the determination of material parameters. The corresponding friction factors and generalized Reynolds numbers are calculated and their relationship examined. Results indicate that the flow of foam follows the same f = 16/NRe,gen...

  17. Evaluation of aqueous-foam surfactants for geothermal drilling fluids

    SciTech Connect (OSTI)

    Rand, P.B.; Montoya, O.J.

    1983-07-01T23:59:59.000Z

    Aqueous foams are potentially useful drilling and cleanout fluids for geothermal applications. Successful use of foams requires surfactants (foaming agents) that can survive in the high-temperature geothermal environment. In this study, solutions of aqueous-foam-forming surfactants have been exposed to 260/sup 0/C (500/sup 0/F) and 310/sup 0/C (590/sup 0/F) in various chemical environments to determine if they can survive and make foams after exposure. Comparison of foams before and after exposure and the change in solution pH were used to evaluate their performance. Controlled liquid-volume-fraction foams, made in a packed-bed foam generator, were used for all tests. These tests have shown that many commercially available surfactants can survive short high-temperature cycles in mild acids, mild bases, and salt solutions as evidenced by their ability to make foams after exposure to high temperatures.

  18. Rapid prototyping: A paradigm shift in investment casting

    SciTech Connect (OSTI)

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

    1996-09-01T23:59:59.000Z

    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.

  19. 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)

    1996-01-01T23:59:59.000Z

    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.

  20. Carbon foams for energy storage devices

    DOE Patents [OSTI]

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

    1996-06-25T23:59:59.000Z

    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.

  1. Materials Science and Engineering A 420 (2006) 8799 Elastic and electric properties of closed-cell aluminum foams

    E-Print Network [OSTI]

    Sevostianov, Igor

    2006-01-01T23:59:59.000Z

    of closed-cell metal foam are assessed based on the experimental measurements. It is shown conductivity of a material due to pores was determined. A non-trivial finding is that the best prediction to mechanical properties) and honeycomb structures (due to environmental properties). Structure and properties

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

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

    process changes also should be investigated to achieve metalcasting without the use of tooling. The industry should investigate the application and blending of statistical, shop...

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

    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 DataDepartment of Energy Your Density Isn't YourTransport(Fact Sheet), GeothermalGridHYDROGENDDepartmentSeptember 20092009 TheBeyond |

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

    E-Print Network [OSTI]

    Moreno, John David

    1991-01-01T23:59:59.000Z

    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 ...

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

    E-Print Network [OSTI]

    Krindinti, Kshipraprasad H

    2002-01-01T23:59:59.000Z

    of Journal of Petroleum Technology. In clnlling. thc ieduced density ol' the foam Fluids, their high solids carrying capacity, and thcii icduced c?tcultition losses;ire among the dcsirablc properties dunng underbalanced drilling operauons. Thc high solids... I I 95 quality foam 10 100 1000 Itlfvatl cheer rate (tiu) Ivlitchcll, 1871 ? - ? Bctcr cl nl. 1878 ? -- ? - 8 nyhnnr and Ikol'u, 1888 Figure 2. 1 Effective viscosity of foam as a function of shear rate and foam quality. From Underbalanced...

  6. Fenton Oxidation of TCE Vapors in a Foam Reactor

    E-Print Network [OSTI]

    Fenton Oxidation of TCE Vapors in a Foam Reactor Eunsung Kan,a,b Seongyup Kim,a and Marc A.interscience.wiley.com). DOI 10.1002/ep.10205 Oxidation of dilute TCE vapors in a foam reactor using Fenton's reagent composition of Fenton's reagents, the foam reactor configuration provided a higher rate absorption and greater

  7. Drainage induced convection rolls in foams (revised version)

    E-Print Network [OSTI]

    Cox, Simon

    , where soap solution is added to the foam at constant flow rate, the irregular motion in the beer glass results for convection in quasi two-dimensional foams (monolayers of bubbles between two glass platesDrainage induced convection rolls in foams (revised version) S. Hutzler, S.J. Cox*, E. Janiaud

  8. 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.

    2015-01-01T23:59:59.000Z

    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.

  9. Furnace atmosphere effects on casting of eutectic superalloys

    SciTech Connect (OSTI)

    Gigliotti, M.F.X.; Greskovich, C.

    1980-02-01T23:59:59.000Z

    Control of furnace atmosphere is a key factor in the use of silica-bonded alumina shell molds for the directional solidification of eutectic superalloys reinforced with tantalum monocarbide whiskers. The use of a furnace atmosphere which is simultaneously oxidizing to aluminum in the eutectic alloy and reducing to silica phases in the mold results in the formation of an alumina barrier layer in situ at the metal/mold interface and an absence of silica phases in the mold region adjacent to this barrier layer. The presence of this microstructure permits castings of eutectics at metal temperatures up to 1750/sup 0/C.

  10. Effect of Heating Rate on Glass Foaming: Transition to Bulk Foam

    SciTech Connect (OSTI)

    Hrma, Pavel R.

    2009-02-15T23:59:59.000Z

    Foaming of glass is an undesirable side effect of glass fining. According to a recent experimental study, the gas-phase volume in the melt heated at a constant rate dramatically increased with an increased rate of heating. This observation indicates that an increased rate of heating (a natural consequence of the increased processing rate experienced as a result of transition to oxy-fuel firing) may exert a substantial influence on glass foaming in advanced glass-melting furnaces. This paper attributes this effect to the change of mode of foam formation in response to an increased rate of heating.

  11. CAST results and Axion review

    E-Print Network [OSTI]

    T. Geralis; for the CAST collaboration

    2009-05-26T23:59:59.000Z

    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.

  12. Compressive properties of a closed-cell aluminum foam as a function of strain-rate and temperature

    SciTech Connect (OSTI)

    Cady, Carl M [Los Alamos National Laboratory; Gray, Ill, George T [Los Alamos National Laboratory; Liu, Cheng [Los Alamos National Laboratory; Lovato, Manuel L [Los Alamos National Laboratory; Mukai, T [JAPAN

    2008-01-01T23:59:59.000Z

    The compressive constitutive behavior of a closed-cell aluminum foam (ALPORAS) manufactured by Shinko Wire Co. in Japan was evaluated under static and dynamic loading conditions as a function of temperature. High-strain-rate tests (1000-2000 s{sup -1}) were conducted using a split-Hopkinson pressure bar (SHPB). Quasi-static and intermediate-strain-rate tests were conducted on a hydraulic load frame. A small but discernable change in the flow stress behavior as a function of strain rate was measured. The deformation behavior of the Al-foam was however found to be strongly temperature dependent under both quasi-static and dynamic loading. Localized deformation and stress state instability during testing of metal foams is discussed in detail since the mechanical behavior over the entire range of strain rates indicates non-uniform deformation. Additionally, investigation of the effect of residual stresses created during manufacturing on the mechanical behavior was investigated.

  13. 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. (Honeywell Federal Manufacturing and Technologies, Kansas City Plant, Kansas City, MO); 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.

    2008-09-01T23:59:59.000Z

    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.

  14. Finite element modeling of syntactic foam.

    SciTech Connect (OSTI)

    Hobbs, Michael L.

    2004-10-01T23:59:59.000Z

    A decomposition model has been developed to predict the response of removable syntactic foam (RSF) exposed to fire-like heat fluxes. RSF consists of glass micro-balloons (GMB) in a cured epoxy polymer matrix. A chemistry model is presented based on the chemical structure of the epoxy polymer, mass transport of polymer fragments to the bulk gas, and vapor-liquid equilibrium. Thermophysical properties were estimated from measurements. A bubble nucleation, growth, and coalescence model was used to describe changes in properties with the extent of reaction. Decomposition of a strand of syntactic foam exposed to high temperatures was simulated.

  15. Magnesium Powertrain Cast Components Project (AMD 304)

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

    block, bore and journal strategies 2.2 Fasteners, gaskets, sealing 2.3 Coolant and corrosion 2.4 FEA design, integration and analysis 2.5 Component casting and casting analysis...

  16. 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.

    1988-06-20T23:59:59.000Z

    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.

  17. DYNAMIC FAILURE OF METALLIC CELLULAR MATERIALS S. LEE and H.D. ESPINOSA

    E-Print Network [OSTI]

    Espinosa, Horacio D.

    interest in the protection design in automotive, locomotive, naval structures, and aerospace. Metallic not observe any rate dependency for the crashing stress of aluminum foams. These discrepancies from different within the specimen at very high strain rates. A model for shock waves in closed cell aluminum foams

  18. Transient foam flow in porous media with CAT Scanner

    SciTech Connect (OSTI)

    Liu, Dianbin; Brigham, W.E.

    1992-03-01T23:59:59.000Z

    Transient behavior is likely to dominate over most of the duration of a foam injection field project. Due to the lack of date, little is presently known about transient foam flow behavior. Foam flow does not follow established models such as the Buckley-Leverett theory, and no general predictive model has been derived. Therefore, both experimental data and a foam flow theory are needed. In this work, foam was injected at a constant mass rate into one-dimensional sandpacks of 1-in diameter and 24-in or 48-in length that had initially been saturate with distilled water. The system was placed in a cat Scanner. Data, obtained at room temperature and low pressure at various times, include both the pressure and saturation distributions. Pressure profiles showed that the pressure gradient is much greater behind the foam front than ahead of it. Moreover, the pressure gradients keep changing as the foam advances in the sandpack. This behavior differs from Buckley-Leverett theory. The CT scan results demonstrated gas channeling near the front, but eventually the foam block all these channels and sweeps the entire cross section after many pore volumes of injection. Three series of experiments were run: (1) surfactant adsorption measurements; (2) gas displacements of surfactant-laden solutions and (3) foam displacements. The first two series of experiments were made to provide the necessary parameters required to match the foam displacements. To this end, it was necessary to smooth the saturation history data, using a Langmuir-type formula. A theory was proposed based on the principles of the fractional flow curve construction method. This foam theory treats the foam as composed of infinitesimal slugs of gas of varying viscosities. The foam front has the lowest viscosity and foam at the injection end has the highest.

  19. Spacetime Foam Model of the Schwarzschild Horizon

    E-Print Network [OSTI]

    Jarmo Makela; Ari Peltola

    2004-03-19T23:59:59.000Z

    We consider a spacetime foam model of the Schwarzschild horizon, where the horizon consists of Planck size black holes. According to our model the entropy of the Schwarzschild black hole is proportional to the area of its event horizon. It is possible to express geometrical arguments to the effect that the constant of proportionality is, in natural units, equal to one quarter.

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

    DOE Patents [OSTI]

    Tan, Seng; Tan, Cher-Dip

    2004-05-11T23:59:59.000Z

    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. Self-Organized Amorphous TiO2 Nanotube Arrays on Porous Ti Foam for Rechargeable Lithium and Sodium Ion Batteries

    SciTech Connect (OSTI)

    Bi, Zhonghe [ORNL; Paranthaman, Mariappan Parans [ORNL; Menchhofer, Paul A [ORNL; Dehoff, Ryan R [ORNL; Bridges, Craig A [ORNL; Chi, Miaofang [ORNL; Guo, Bingkun [ORNL; Sun, Xiao-Guang [ORNL; Dai, Sheng [ORNL

    2013-01-01T23:59:59.000Z

    Self-organized amorphous TiO2 nanotube arrays (NTAs) were successfully fabricated on both Ti foil and porous Ti foam through electrochemical anodization techniques. The starting Ti foams were fabricated using ARCAM s Electron Beam Melting (EBM) technology. The TiO2 NTAs on Ti foam were used as anodes in lithium ion batteries; they exhibited high capacities of 103 Ahcm-2 at 10 Acm-2 and 83 Ahcm-2 at 500 Acm-2, which are two to three times higher than those achieved on the standard Ti foil, which is around 40 Ahcm-2 at 10 Acm-2 and 24 Ahcm-2 at 500 Acm-2, respectively. This improvement is mainly attributed to higher surface area of the Ti foam and higher porosity of the nanotube arrays layer grown on the Ti foam. In addition, a Na-ion half-cell composed of these NTAs anodes and Na metal showed a self-improving specific capacity upon cycling at 10 Acm-2. These results indicate that TiO2 NTAs grown on Ti porous foam are promising electrodes for Li-ion or Na-ion rechargeable batteries.

  2. Effect of furnace atmosphere on E-glass foaming

    SciTech Connect (OSTI)

    Kim, Dong-Sang; Dutton, Bryan C.; Hrma, Pavel R.; Pilon, Laurent

    2006-12-01T23:59:59.000Z

    The effect of furnace atmosphere on E-glass foaming generated in crucible has been studied with a specific goal to understand the impact of increased water content on foaming in oxy-fired furnaces. E-glass foams were generated in a fused-quartz crucible located in a quartz window furnace equipped with video recording. The present study showed that humidity in the furnace atmosphere destabilizes foam, while other gases have little effect on foam stability. This study suggests that the higher foaming in oxy-fired furnace compared to air-fired is caused by the effect of water on early sulfate decomposition, promoting more efficient refining gas generation from sulfate (known as ďdilution effectĒ).

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

    SciTech Connect (OSTI)

    Kuyucak, Selcuk [CanmetMATERIALS; Li, Delin [CanmetMATERIALS

    2013-12-31T23:59:59.000Z

    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.

  4. The impact of microstructure on the permeability of metal foams

    E-Print Network [OSTI]

    Medraj, Mamoun

    a schematic diagram of Darcy's flow. Darcy proposed an empirical equation for estimating the volumetric flow data on widely accepted quadratic model of Hazen-Dupuit- Darcy. Generally, the experimental results and their use in new applications is expected to grow in the near future. CSME 2004 Forum 220 Q Figure 1: Darcy

  5. Military housing foam application and analysis

    SciTech Connect (OSTI)

    Torres, J. J.

    2012-03-01T23:59:59.000Z

    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.

  6. Dynamical Heterogeneities in Grains and Foams

    E-Print Network [OSTI]

    Olivier Dauchot; Douglas J. Durian; Martin van Hecke

    2010-10-05T23:59:59.000Z

    Dynamical heterogeneities have been introduced in the context of the glass transition of molecular liquids and the lengthscale associated with them has been argued to be at the origin of the observed quasi-universal behaviour of glassy systems. Dense amorphous packings of granular media and foams also exhibit slow dynamics, intermittency and heterogeneities. We review a number of recent experimental studies of these systems, where one has direct access to the relevant space-time dynamics, allowing for direct visualisations of the dynamical heterogeneities. On one hand these visualisations provide a unique opportunity to access the microscopic mechanisms responsible for the growth of dynamical correlations. On the other hand focussing on the differences in these heterogeneities in microscopically different systems allows to discuss the range of the analogies between molecular thermal glasses and athermal glasses such as granular media and foams. Finally this review is the opportunity to discuss various approaches to actually extract quantitatively the dynamical lengthscale from experimental data.

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

    SciTech Connect (OSTI)

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

    2006-03-15T23:59:59.000Z

    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.

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

    E-Print Network [OSTI]

    Lee, Gary Chiaray

    2011-01-01T23:59:59.000Z

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

  9. Multifunctional Corrosion-resistant Foamed Well Cement Composites

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

    Multifunctional Corrosion-resistant Foamed Well Cement Composites Project Officer: Dan KingGreg Stillman Total budget: 300 K April 24 , 2013 Principal Investigator: Dr. Toshifumi...

  10. Design of composite plastic foams for improved cushioning

    E-Print Network [OSTI]

    Eskew, James Oliver

    1989-01-01T23:59:59.000Z

    and Polyethylene Foams at 0. 5G w/ 0. 444 psi Static Load 36 37 41 16. Example of a Parallel Configuration with Polyurethane and Polyethylene Foams at 0. 5G w/ 0. 311 psi Static Load on Composite . 41 17. Single Polyurethane Foam at 0. 5G w/ 0. 156 psi... w/ 0. 444 psi Static Load 45 45 53 54 55 57 57 58 58 59 59 60 60 LIST OF FIGURES (Continued) Figure Page 33 34 35 36 37 38. 40. 41 42. 43 44. 45 Single Polyethylene Foam at 0. 5G w/ 0. 156 psi Static Load Single...

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

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

    Carbon Foam Thermal Management Materials for Electronic Packaging David P. Stinton Oak Ridge National Laboratory Project Team: Nidia C. Gallego, ORNL Brian Thompson, ThermalCentric...

  12. 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)

    2015-04-24T23:59:59.000Z

    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?/Zn≤? 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.

  13. 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.

    2015-04-24T23:59:59.000Z

    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†Ľto 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?/Zn≤? 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.ę†less

  14. Gating of Permanent Molds for ALuminum Casting

    SciTech Connect (OSTI)

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

    2004-03-30T23:59:59.000Z

    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.

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

    SciTech Connect (OSTI)

    Nagaswaran, R.; Limaye, S.Y.

    1996-02-01T23:59:59.000Z

    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.

  16. 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;

  17. Nonaqueous composition for slip casting or cold forming refractory material into solid shapes

    SciTech Connect (OSTI)

    Montgomery, L.C.

    1993-08-24T23:59:59.000Z

    A composition is described for slip casting or cold forming non-oxide refractory material(s) into solid shape comprising finely divided solid refractory materials selected from the group consisting of metal boride, refractory carbide, nitride, silicide and a refractory metal of tungsten, molybdenum, tantalum and chromium suspended in a nonaqueous liquid slip composition consisting essentially of a deflocculent composed of a vinyl chloride-vinyl acetate resin dissolved in an organic solvent.

  18. 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.

    1996-09-01T23:59:59.000Z

    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.

  19. In-situ conditioning of a strip casting roll

    DOE Patents [OSTI]

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

    1997-01-01T23:59:59.000Z

    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.

  20. In-situ conditioning of a strip casting roll

    DOE Patents [OSTI]

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

    1997-07-29T23:59:59.000Z

    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.

  1. 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

    2007-03-30T23:59:59.000Z

    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.

  2. Spray casting project final report

    SciTech Connect (OSTI)

    Churnetski, S.R.; Thompson, J.E.

    1996-08-01T23:59:59.000Z

    Lockheed Martin Energy Systems, Inc. (Energy Systems), along with other participating organizations, has been exploring the feasibility of spray casting depleted uranium (DU) to near-net shape as a waste minimization effort. Although this technology would be useful in a variety of applications where DU was the material of choice, this effort was aimed primarily at gamma-shielding components for use in storage and transportation canisters for high-level radioactive waste, particularly in the Multipurpose Canister (MPC) application. In addition to the waste-minimization benefits, spray casting would simplify the manufacturing process by allowing the shielding components for MPC to be produced as a single component, as opposed to multiple components with many fabrication and assembly steps. In earlier experiments, surrogate materials were used to simulate the properties (specifically reactivity and density) of DU. Based on the positive results from those studies, the project participants decided that further evaluation of the issues and concerns that would accompany spraying DU was warranted. That evaluation occupied substantially all of Fiscal Year 1995, yielding conceptual designs for both an intermediate facility and a production facility and their associated engineering estimates. An intermediate facility was included in this study to allow further technology development in spraying DU. Although spraying DU to near-net shape seems to be feasible, a number of technical, engineering, and safety issues would need to be evaluated before proceeding with a production facility. This report is intended to document the results from the spray-casting project and to provide information needed by anyone interested in proceeding to the next step.

  3. Edinburgh College of Art : cast collection and architecture†

    E-Print Network [OSTI]

    Stoica, Ruxandra-Iulia; Stewart, Margaret

    2012-01-01T23:59:59.000Z

    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...

  4. 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 used bioreactors for air pollution control. © 2003 Wiley Periodicals, Inc. Biotechnol Bioeng 84: 240≠244, 2003. Keywords: VOC control; biofilter; air pollution control; toluene; biologically activated foam

  5. Continuous Operation of Foamed Emulsion Bioreactors Treating Toluene Vapors

    E-Print Network [OSTI]

    Continuous Operation of Foamed Emulsion Bioreactors Treating Toluene Vapors Eunsung Kan, Marc A.interscience.wiley.com). DOI: 10.1002/bit.20619 Abstract: Continuous operation of a new bioreactor for air pollution control called the foamed emulsion bioreactor (FEBR) has been investigated. The effect of several liquid feeding

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

    E-Print Network [OSTI]

    ARTICLE Modeling of a Foamed Emulsion Bioreactor: II. Model Parametric Sensitivity Eunsung Kan: The sensitivity of a conceptual model of a foam emulsion bioreactor (FEBR) used for the control of toluene vapors mass transfer and kinetic limitations can coexist in the bioreactor system. These results will help

  7. Mechanical Inhibition of Foam Formation via a Rotating Nozzle

    E-Print Network [OSTI]

    Ristenpart, William

    have been devel- oped to minimize the impact of foams [2]. Anti-foaming agents are added to prevent environmental disposal problems, and increase the overall process cost and complexity [3]. Non report a design for a rotating nozzle that prevents successive collocated impacts, thereby minimizing

  8. Mechanical properties and energy absorption characteristics of a polyurethane foam

    SciTech Connect (OSTI)

    Goods, S.H.; Neuschwanger, C.L.; Henderson, C.; Skala, D.M.

    1997-03-01T23:59:59.000Z

    Tension, compression and impact properties of a polyurethane encapsulant foam have been measured as a function of foam density. Significant differences in the behavior of the foam were observed depending on the mode of testing. Over the range of densities examined, both the modulus and the elastic collapse stress of the foam exhibited power-law dependencies with respect to density. The power-law relationship for the modulus was the same for both tension and compression testing and is explained in terms of the elastic compliance of the cellular structure of the foam using a simple geometric model. Euler buckling is used to rationalize the density dependence of the collapse stress. Neither tension nor compression testing yielded realistic measurements of energy absorption (toughness). In the former case, the energy absorption characteristics of the foam were severely limited due to the inherent lack of tensile ductility. In the latter case, the absence of a failure mechanism led to arbitrary measures of energy absorption that were not indicative of true material properties. Only impact testing revealed an intrinsic limitation in the toughness characteristics of the material with respect to foam density. The results suggest that dynamic testing should be used when assessing the shock mitigating qualities of a foam.

  9. Environmentally-benign Flame Retardant Nanocoating for Foam and Fabric

    E-Print Network [OSTI]

    Cain, Amanda Ashley

    2014-12-09T23:59:59.000Z

    wt% coating addition) are necessary to cut the pkHRR of polyether-based polyurethane by 54.8%, relative to control, uncoated foam. The influence of clay aspect ratio and composition on fire behavior of coated polyurethane foam was studied as a...

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

    SciTech Connect (OSTI)

    McIntyre, Annie

    2010-11-01T23:59:59.000Z

    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.

  11. Recovery of flexible polyurethane foam from shredder residue.

    SciTech Connect (OSTI)

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

    1999-06-29T23:59:59.000Z

    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.

  12. Foams and granular media known state of mat-

    E-Print Network [OSTI]

    Cox, Simon

    Foams and granular media 2 known state of mat- design glasses with de- perties on an industrial n disordered ail in this review, mod- proaches to the glass ledge of advanced liq- renormalization group, FIG a broad range of lengthscales, such as atomic (top left), colloidal (top right) systems, but also in foams

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

    SciTech Connect (OSTI)

    Christoph Beckermann; Kent Carlson

    2011-07-22T23:59:59.000Z

    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√?¬?√?¬Ę√?¬?√?¬?√?¬?√?¬?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√?¬?√?¬?√?¬?√?¬įC. 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√?¬?√?¬Ę√?¬?√?¬?√?¬?√?¬?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.

  14. AcademiCast Transcript Texas Tech University

    E-Print Network [OSTI]

    Rock, Chris

    and Research in the College of Education, is the premier center in West TexasAcademiCast Transcript Texas Tech University December 12, 2012 Irlbeck: This is AcademiCast--Texas Tech University's podcast series from the Office of the Provost

  15. RELIABILITY-BASED CASTING PROCESS DESIGN OPTIMIZATION

    E-Print Network [OSTI]

    Beckermann, Christoph

    RELIABILITY-BASED CASTING PROCESS DESIGN OPTIMIZATION Richard Hardin1 , K.K. Choi1 , and Christoph 52242-1527 Keywords: Casting Process Design, Optimization, Reliability-Based Design Optimization purpose reliability-based design optimization (RBDO) software tool previously developed at the University

  16. Dimensional variability of production steel castings

    SciTech Connect (OSTI)

    Peters, F.E.; Risteu, J.W.; Vaupel, W.G.; DeMeter, E.C.; Voigt, R.C.

    1994-12-31T23:59:59.000Z

    Work is ongoing to characterize the dimensional variability of steel casting features. Data are being collected from castings produced at representative Steel Founders` Society of America foundries. Initial results based on more than 12,500 production casting feature measurements are presented for carbon and low alloy steel castings produced in green sand, no-bake, and shell molds. A comprehensive database of casting, pattern, and feature variables has been developed so that the influence of the variables on dimensional variability can be determined. Measurement system analysis is conducted to insure that large measurement error is not reported as dimensional variability. Results indicate that the dimensional variability of production casting features is less than indicated in current US (SFSA) and international (ISO) standards. Feature length, casting weight, parting line and molding process all strongly influence dimensional variability. Corresponding pattern measurements indicate that the actual shrinkage amount for casting features varies considerably. This variation in shrinkage will strongly influence the ability of the foundry to satisfy customer dimensional requirements.

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

    E-Print Network [OSTI]

    Cambridge, University of

    2022-01-01T23:59:59.000Z

    and the surface finish is good. A heat≠resistant 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

  18. 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...

  19. PNNL: Mechanistic-Based Ductility Prediction for Complex Mg Castings...

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

    PNNL: Mechanistic-Based Ductility Prediction for Complex Mg Castings PNNL: Mechanistic-Based Ductility Prediction for Complex Mg Castings 2012 DOE Hydrogen and Fuel Cells Program...

  20. Method of forming a foamed thermoplastic polymer

    DOE Patents [OSTI]

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

    1984-11-21T23:59:59.000Z

    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. Growth of aqueous foam on flexible membranes

    E-Print Network [OSTI]

    Hiroyuki Shima

    2009-05-30T23:59:59.000Z

    In this paper, I study the coarsening dynamics of two-dimensional dry foam sandwiched by deformable membranes. The time-varying deformation of the confining membranes gives rise to a significant alteration in the evolution of polygonal cells of bubbles when compared to the case of rigid membranes. This alteration is attributed to the correlation between the rate of inter-cell gas transfer and temporal fluctuation in surface curvature within a cell domain. The existing material constants are referred to understand the utility of the correlation effect toward the artificial control of the coarsening dynamics.

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

    DOE Patents [OSTI]

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

    1991-11-12T23:59:59.000Z

    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.

  3. Fusion Engineering and Design 81 (2006) 455460 Breeder foam: an innovative low porosity solid breeder material

    E-Print Network [OSTI]

    Ghoniem, Nasr M.

    2006-01-01T23:59:59.000Z

    ; Foam processing; Foam applications 1. Introduction Solid breeder blanket concepts are typically based structural and Be material requirements in a breeder blanket. However, high density Li-ceramic foams haveFusion Engineering and Design 81 (2006) 455≠460 Breeder foam: an innovative low porosity solid

  4. Hybrid fiber reinforced Composite Phenolic foam Amit Desai, Steven R. Nutt

    E-Print Network [OSTI]

    Southern California, University of

    Composite Center Hybrid Composite Phenolic foams were reinforced with glass and aramid fibers in different the hybrid foams exhibited higher strength and modulus as compared to foams reinforced with only glass with only glass fibers of different length , the elastic properties of foam such as modulus and density do

  5. Foam flow around an obstacle: obstacle-wall interaction , B. Dollet2

    E-Print Network [OSTI]

    Cox, Simon

    two-dimensional (2D) foams, such as can be made by squeezing a foam between two glass plates soFoam flow around an obstacle: obstacle-wall interaction S.J. Cox1 , B. Dollet2 , F. Graner2 1- chanics, University of Wales Aberystwyth, Ceredigion SY23 3BZ, UK, e-mail: foams@aber.ac.uk 2 Spectrom

  6. Localization of topological changes in Couette and Poiseuille flows of two-dimensional foams

    E-Print Network [OSTI]

    Cox, Simon

    -dimensional (2D) foams, such as can be made by squeezing a foam between parallel glass plates until it consistsLocalization of topological changes in Couette and Poiseuille flows of two-dimensional foams S. Quasistatic simulations show that the topological changes or plastic events that occur when an aqueous foam

  7. 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)

    1990-01-01T23:59:59.000Z

    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.

  8. Materials Applications for Non-Lethal: Aqueous Foams

    SciTech Connect (OSTI)

    GOOLSBY,TOMMY D.; SCOTT,STEVEN H.

    1999-09-15T23:59:59.000Z

    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. 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)

    2003-04-01T23:59:59.000Z

    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.

  10. Examination of the solidification macrostructure of spheroidal and flake graphite cast irons using DAAS and ESBD

    SciTech Connect (OSTI)

    Rivera, G. [Metallurgy Division INTEMA, National University of Mar del Plata, CONICET, J. B. Justo 4302 (B7608FDQ) Mar del Plata (Argentina); Calvillo, P.R. [Department of Metallurgy and Materials Science, Ghent University (Belgium); Boeri, R. [Metallurgy Division INTEMA, National University of Mar del Plata, CONICET, J. B. Justo 4302 (B7608FDQ) Mar del Plata (Argentina)], E-mail: boeri@fi.mdp.edu.ar; Houbaert, Y. [Department of Metallurgy and Materials Science, Ghent University (Belgium); Sikora, J. [Metallurgy Division INTEMA, National University of Mar del Plata, CONICET, J. B. Justo 4302 (B7608FDQ) Mar del Plata (Argentina)], E-mail: jsikora@fi.mdp.edu.ar

    2008-09-15T23:59:59.000Z

    This investigation focuses on the study of the solidification macrostructure of sand cast flake and spheroidal graphite cast irons. The macrostructure is revealed by using a special technique developed earlier by the authors, called Direct Austempering After Solidification. The observations make use of conventional metallography and Electron Back Scattering Diffraction. The latter technique allows a more detailed observation of the morphology of the austenite grains and the microstructure of the matrix. The results of Electron Back Scattering Diffraction validate the observations made using the macrographic technique. It is verified that the solidification of both flake and spheroidal graphite cast irons is dominated by the growth of large austenite dendrites that form a grain pattern similar to that usually found in most metallic alloys.

  11. A high resolution finite volume method for efficient parallel simulation of casting processes on unstructured meshes

    SciTech Connect (OSTI)

    Kothe, D.B.; Turner, J.A.; Mosso, S.J. [Los Alamos National Lab., NM (United States); Ferrell, R.C. [Cambridge Power Computer Assoc. (United States)

    1997-03-01T23:59:59.000Z

    We discuss selected aspects of a new parallel three-dimensional (3-D) computational tool for the unstructured mesh simulation of Los Alamos National Laboratory (LANL) casting processes. This tool, known as {bold Telluride}, draws upon on robust, high resolution finite volume solutions of metal alloy mass, momentum, and enthalpy conservation equations to model the filling, cooling, and solidification of LANL castings. We briefly describe the current {bold Telluride} physical models and solution methods, then detail our parallelization strategy as implemented with Fortran 90 (F90). This strategy has yielded straightforward and efficient parallelization on distributed and shared memory architectures, aided in large part by new parallel libraries {bold JTpack9O} for Krylov-subspace iterative solution methods and {bold PGSLib} for efficient gather/scatter operations. We illustrate our methodology and current capabilities with source code examples and parallel efficiency results for a LANL casting simulation.

  12. Gravity as Quantum Foam In-Flow

    E-Print Network [OSTI]

    Cahill, R T

    2003-01-01T23:59:59.000Z

    The new information-theoretic Process Physics provides an explanation of space as a quantum foam system in which gravity is an inhomogeneous flow of the quantum foam into matter. The older Newtonian and General Relativity theories for gravity are analysed. It is shown that Newtonian gravity may be written in the form of an in-flow. General Relativity is also analysed as an in-flow, for those cases where it has been tested. An analysis of various experimental data demonstrates that absolute motion relative to space has been observed by Michelson and Morley, Miller, Illingworth, Jaseja et al, Torr and Kolen, and by DeWitte. The Dayton Miller and Roland DeWitte data also reveal the in-flow of space into matter which manifests as gravity. The experimental data suggests that the in-flow is turbulent, which amounts to the observation of a gravitational wave phenomena. A new in-flow theory of gravity is proposed which passes all the tests that General Relativity was claimed to have passed, but as well the new theory...

  13. Gravity as Quantum Foam In-Flow

    E-Print Network [OSTI]

    Reginald T Cahill

    2003-07-01T23:59:59.000Z

    The new information-theoretic Process Physics provides an explanation of space as a quantum foam system in which gravity is an inhomogeneous flow of the quantum foam into matter. The older Newtonian and General Relativity theories for gravity are analysed. It is shown that Newtonian gravity may be written in the form of an in-flow. General Relativity is also analysed as an in-flow, for those cases where it has been tested. An analysis of various experimental data demonstrates that absolute motion relative to space has been observed by Michelson and Morley, Miller, Illingworth, Jaseja et al, Torr and Kolen, and by DeWitte. The Dayton Miller and Roland DeWitte data also reveal the in-flow of space into matter which manifests as gravity. The experimental data suggests that the in-flow is turbulent, which amounts to the observation of a gravitational wave phenomena. A new in-flow theory of gravity is proposed which passes all the tests that General Relativity was claimed to have passed, but as well the new theory suggests that the so-called spiral galaxy rotation-velocity anomaly may be explained without the need of `dark matter'. Various other gravitational anomalies also appear to be explainable. Newtonian gravity appears to be strictly valid only outside of spherically symmetric matter systems.

  14. Mechanical Properties of Bulk Metallic Glasses and Composites

    E-Print Network [OSTI]

    Lee, M.L.

    We have studied the mechanical properties of monolithic bulk metallic glasses and composite in the La based alloys. La???yAl??(Cu, Ni)y (y=24 to 32) alloy systems was used to cast the ...

  15. Characterization of Technetium Speciation in Cast Stone

    SciTech Connect (OSTI)

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

    2013-11-11T23:59:59.000Z

    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, ďProduction and Long-Term Performance of Low Temperature Waste FormsĒ 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.

  16. Note and calculations concerning elastic dilatancy in 2D glass-glass liquid foams

    E-Print Network [OSTI]

    FranÁois Molino; Pierre Rognon; Cyprien Gay

    2010-10-30T23:59:59.000Z

    When deformed, liquid foams tend to raise their liquid contents like immersed granular materials, a phenomenon called dilatancy. We have aready described a geometrical interpretation of elastic dilatancy in 3D foams and in very dry foams squeezed between two solid plates (2D GG foams). Here, we complement this work in the regime of less dry 2D GG foams. In particular, we highlight the relatively strong dilatancy effects expected in the regime where we have predicted rapid Plateau border variations.

  17. ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2009

    E-Print Network [OSTI]

    Colton, Jonathan S.

    ≠ Air (oxygen), vacuum, inert gas (argon) ∑ Heating ≠ External - electric, gas, oil ≠ Internal Prof. J.S. Colton © GIT 2009 11 Processes ∑ Sand ∑ Shell ∑ Plaster ∑ Ceramic ∑ Investment ∑ Lost foam Metals processed by casting ∑ Sand casting ≠ 60% ∑ Investment casting ≠ 7% ∑ Die casting ≠ 9% ∑ Permanent

  18. 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)

    2012-07-01T23:59:59.000Z

    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)

  19. Aspiration tests in aqueous foam using a breathing simulator

    SciTech Connect (OSTI)

    Archuleta, M.M.

    1995-12-01T23:59:59.000Z

    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.

  20. Toxicity evaluation and hazard review for Rigid Foam

    SciTech Connect (OSTI)

    Archuleta, M.M.; Stocum, W.E.

    1994-02-01T23:59:59.000Z

    Rigid Foam is a chemical delay foam used to completely encapsulate an object or to block access to an area. Prior studies have indicated that the final foam product is essentially non-toxic. The purpose of this study was to evaluate and summarize the current chemical and toxicological data available on the components of Rigid Foam and to update the information available on the toxicity of the final Rigid Foam product. Since the possibility exists for a partial deployment of Rigid Foam where only one of the components is released, this study also examined the toxicity of its chemical constituents. Rigid Foam is composed of an {open_quotes}A{close_quotes} and {open_quotes}B{close_quotes} Component. The {open_quotes}A{close_quotes} component is primarily a polymeric isocyanate and the {open_quotes}B{close_quotes} component is a mixture of polyols. In addition to the primary constituents, dichlorodifluoromethane and trichlorofluoromethane are present as blowing agents along with catalysts and silicone surfactants necessary for foaming. The pre-deployed {open_quotes}A{close_quotes} and {open_quotes}B{close_quotes} components are stored in separate vessels and are brought together in static mixing nozzles for dispersal. The results of this evaluation indicate that a completely deployed Rigid Foam under normal conditions is essentially non-toxic as determined previously. However, in the event of a partial deployment or deployment of an individual component directly at an unprotected individual, the degree of hazard is increased due to the toxic and corrosive nature of the individual constituents. The health hazard would depend on the properties of the material to which the person was exposed.

  1. Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking

    SciTech Connect (OSTI)

    Das, Subodh K.

    2006-01-09T23:59:59.000Z

    A successful four-year project on the modeling and optimization of direct chill (DC) casting to reduce ingot cracking has been completed. The project involved close collaboration among private industries, national laboratories, and universities. During the four-year project, 16 quarterly meetings brought the industrial partners and the research team together for discussion of 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. The collaborative research resulted in several major accomplishments or findings: (1) Surface cracks were shown to be a result of hot tearing rather than cold cracks, as was thought before this project. These cracks form on the surface of a DC cast ingot just above the impingement point of the secondary cooling water jets. The cracks form along dendrite and grain boundaries, where solute and impurity elements are highly segregated. This understanding led to the development of a new technique for determining the mechanical properties in the nonequilibrium mushy zone of alloys and to thermodynamic predictions of the hot tearing propensity of DC cast ingots. (2) The apparent heat transfer coefficient (HTC) at the ingot surface in the water cooling region during DC casting was determined on the basis of temperature measurements in commercial DC casting ingots and an inverse heat transfer analysis. HTCs were calculated as a function of temperature and time, and covered the different regimes of heat transfer expected during DC casting. The calculated values were extrapolated to include the effect of water flow rate. The calculated HTCs had a peak at around 200 C, corresponding to the high heat transfer rates during nucleate boiling, and the profile was consistent with similar data published in the literature. (3) A new method, termed the reheating-cooling method (RCM), was developed and validated for measuring mechanical properties in the nonequilibrium mushy zones of alloys. The new method captures the brittle nature of aluminum alloys at temperatures close to the nonequilibrium solidus temperature, while specimens tested using the reheating method exhibit significant ductility. The RCM has been used for determining the mechanical properties of alloys at nonequilibrium mushy zone temperatures. Accurate data obtained during this project show that the metal becomes more brittle at high temperatures and high strain rates. (4) The elevated-temperature mechanical properties of the alloy were determined. Constitutive models relating the stress and strain relationship at elevated temperatures were also developed. The experimental data fit the model well. (5) An integrated 3D DC casting model has been used to simulate heat transfer, fluid flow, solidification, and thermally induced stress-strain during casting. A temperature-dependent HTC between the cooling water and the ingot surface, cooling water flow rate, and air gap were coupled in this model. An elasto-viscoplastic model based on high-temperature mechanical testing was used to calculate the stress during casting. The 3D integrated model can be used for the prediction of temperature, fluid flow, stress, and strain distribution in DC cast ingots. (6) The cracking propensity of DC cast ingots can be predicted using the 3D integrated model as well as thermodynamic models. Thus, an ingot cracking index based on the ratio of local stress to local alloy strength was established. Simulation results indicate that cracking propensity increases with increasing casting speed. The composition of the ingots also has a major effect on cracking formation. It was found that copper and zinc increase the cracking propensity of DC cast ingots. The goal of this Aluminum Industry of the Future (IOF) project was to assist the aluminum industry in reducing the incidence of stress cracks in DC castings from a current level of 5% down to 2%. This could lead to energy savings

  2. Present status and future prospects of electro-magnetic casting for silicon solar cells

    SciTech Connect (OSTI)

    Kaneko, Kyojiro; Kawamura, Ritsuo; Misawa, Teruoki [Sumitomo SiTiX Corp., Amagasaki, Hyogo (Japan). Research and Development Center

    1994-12-31T23:59:59.000Z

    The development research of Electro-Magnetic Casting (EMC) for silicon crystal manufacturing technology has been carried out for years with the purpose of providing low cost multicrystalline silicon substrate for solar cells. The EMC technology is a new concept, in which electromagnetic force is utilized to suspend molten metal without contact to crucible wall for melting and solidification of silicon material. At present, the research has been carried out for the development of casting technique with an ingot size of 22 x 22 cm{sup 2} cross section, and the furnace construction for producing a 35 x 35 cm{sup 2} cross sectioned ingot has been begun. Solar cell conversion efficiencies using EMC ingot crystals are ranging from 13--14% at the present, and the quality of EMC material reaches within that of conventional mold casting material. By the improvements of higher casting speed, higher material quality and larger ingot size at the EMC technology, it is expected that a new casting technique for lower cost ingot production will be realized. The paper describes the features of EMC technology, the silicon EMC furnace, crystalline properties of EMC ingots, electric power consumption of EMC, and cost comparison of the EMC and Czychralski pulling methods.

  3. Note and calculations concerning elastic dilatancy in 2D glassglass liquid foams Francois Molino, Pierre Rognon, and Cyprien Gay #

    E-Print Network [OSTI]

    Recanati, Catherine

    Note and calculations concerning elastic dilatancy in 2D glass¬≠glass liquid foams Fran‚?ļcois Molino: October 30, 2010) When deformed, liquid foams tend to raise their liquid contents like immersed granular dilatancy in 3D foams and in very dry foams squeezed between two solid plates (2D GG foams). Here, we

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

    SciTech Connect (OSTI)

    David Schwam

    2012-12-15T23:59:59.000Z

    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.

  5. Thermal transport properties of grey cast irons

    SciTech Connect (OSTI)

    Hecht, R.L. [Ford Motor Co., Dearborn, MI (United States). Ford Research Lab.; Dinwiddie, R.B.; Porter, W.D.; Wang, Hsin [Oak Ridge National Lab., TN (United States)

    1996-10-01T23:59:59.000Z

    Thermal diffusivity and thermal conductivity of grey cast iron have been measured as a function of graphite flake morphology, chemical composition, and position in a finished brake rotor. Cast iron samples used for this investigation were cut from ``step block`` castings designed to produce iron with different graphite flake morphologies resulting from different cooling rates. Samples were also machined from prototype alloys and from production brake rotors representing a variation in foundry practice. Thermal diffusivity was measured at room and elevated temperatures via the flash technique. Heat capacity of selected samples was measured with differential scanning calorimetry, and these results were used to calculate the thermal conductivity. Microstructure of the various cast iron samples was quantified by standard metallography and image analysis, and the chemical compositions were determined by optical emission spectroscopy.

  6. AcademiCast Transcript Texas Tech University

    E-Print Network [OSTI]

    Rock, Chris

    West Texas' quail population. The region's quail numbers plummeted in 2010 in West Texas and western Oklahoma. So far, scientists have found lead, mercuryAcademiCast Transcript Texas Tech University August 30, 2013 Pierce

  7. Mini-PROTEAN Multi-Casting Chamber

    E-Print Network [OSTI]

    Raizada, Manish N.

    ļC for future use. 1.2 Specifications Materials of construction Clamps Glass filled polycarbonate Casting chamber, sealing plate Molded polycarbonate Gasket Silicone tubing Overall size 10 cm x 10 cm x 16

  8. Industrial motivations: Conceptual Automotive Styling Tools (CAST)

    E-Print Network [OSTI]

    Toronto, University of

    Industrial motivations: Conceptual Automotive Styling Tools (CAST) Karan Singh #12;Conceptual. ∑ What makes automotive design unique. ∑ Existing modeling trends. ∑ A proposed workflow for conceptual automotive design. #12;Conceptual design desirables ∑ Abstraction from underlying surface math. ∑ Invite

  9. CPUF - a chemical-structure-based polyurethane foam decomposition and foam response model.

    SciTech Connect (OSTI)

    Fletcher, Thomas H. (Brigham Young University, Provo, UT); Thompson, Kyle Richard; Erickson, Kenneth L.; Dowding, Kevin J.; Clayton, Daniel (Brigham Young University, Provo, UT); Chu, Tze Yao; Hobbs, Michael L.; Borek, Theodore Thaddeus III

    2003-07-01T23:59:59.000Z

    A Chemical-structure-based PolyUrethane Foam (CPUF) decomposition model has been developed to predict the fire-induced response of rigid, closed-cell polyurethane foam-filled systems. The model, developed for the B-61 and W-80 fireset foam, is based on a cascade of bondbreaking reactions that produce CO2. Percolation theory is used to dynamically quantify polymer fragment populations of the thermally degrading foam. The partition between condensed-phase polymer fragments and gas-phase polymer fragments (i.e. vapor-liquid split) was determined using a vapor-liquid equilibrium model. The CPUF decomposition model was implemented into the finite element (FE) heat conduction codes COYOTE and CALORE, which support chemical kinetics and enclosure radiation. Elements were removed from the computational domain when the calculated solid mass fractions within the individual finite element decrease below a set criterion. Element removal, referred to as ?element death,? creates a radiation enclosure (assumed to be non-participating) as well as a decomposition front, which separates the condensed-phase encapsulant from the gas-filled enclosure. All of the chemistry parameters as well as thermophysical properties for the CPUF model were obtained from small-scale laboratory experiments. The CPUF model was evaluated by comparing predictions to measurements. The validation experiments included several thermogravimetric experiments at pressures ranging from ambient pressure to 30 bars. Larger, component-scale experiments were also used to validate the foam response model. The effects of heat flux, bulk density, orientation, embedded components, confinement and pressure were measured and compared to model predictions. Uncertainties in the model results were evaluated using a mean value approach. The measured mass loss in the TGA experiments and the measured location of the decomposition front were within the 95% prediction limit determined using the CPUF model for all of the experiments where the decomposition gases were vented sufficiently. The CPUF model results were not as good for the partially confined radiant heat experiments where the vent area was regulated to maintain pressure. Liquefaction and flow effects, which are not considered in the CPUF model, become important when the decomposition gases are confined.

  10. 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)

    1997-01-01T23:59:59.000Z

    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.}

  11. 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)

    1996-06-01T23:59:59.000Z

    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.

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

    E-Print Network [OSTI]

    Sarzynski, Melanie Diane

    2004-09-30T23:59:59.000Z

    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 and other commercial...

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

    E-Print Network [OSTI]

    Sarzynski, Melanie Diane

    2004-09-30T23:59:59.000Z

    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 and other commercial...

  14. 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

    2007-01-01T23:59:59.000Z

    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.

  15. 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. GalŠn; J. A. GarcŪa; 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. TomŠs; T. Vafeiadis; J. K. Vogel

    2015-03-17T23:59:59.000Z

    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.

  16. 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)

    2006-08-15T23:59:59.000Z

    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

  17. Process for producing carbon foams for energy storage devices

    DOE Patents [OSTI]

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

    1998-08-04T23:59:59.000Z

    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.

  18. 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)

    1998-01-01T23:59:59.000Z

    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.

  19. 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 onYouTube YouTube Note: Since the.pdfBreaking of BlytheDepartment of Energy IRS Issuesof the U.S.Profile:Program |

  20. 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 DataDepartment of Energy Your Density Isn't Your Destiny:RevisedAdvisoryStandard |inHVACEnforcementEngagingVehicle TechnologiesEnergy

  1. NDE 701: Enhanced Resonance Inspection for 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 DataDepartment of Energy Your Density Isn'tOrigin of Contamination in Many Devils Wash, Shiprock, NewThis paper hasNC-1-BNational

  2. 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 DataDepartment of Energy Your Density Isn't YourTransport(Fact Sheet), GeothermalGridHYDROGENDDepartmentSeptember 20092009 TheBeyond

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

    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 DataDepartment of Energy Your Density Isn't YourTransport(Fact Sheet), GeothermalGridHYDROGENDDepartmentSeptember 20092009

  4. 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 DataDepartment of Energy Your Density Isn'tOrigin of ContaminationHubs+18,new2004_v1.3_5.0.zipFlorida4Visitors Chapter 5.1 (March

  5. Methods and apparatuses for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    DOE Patents [OSTI]

    Stoddard, Nathan G. (Gettysburg, PA)

    2011-11-01T23:59:59.000Z

    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.

  6. Methods and apparatus for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    DOE Patents [OSTI]

    Stoddard, Nathan G

    2014-01-14T23:59:59.000Z

    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.

  7. Microstructure of thin-wall ductile iron castings

    SciTech Connect (OSTI)

    Dogan, Omer N.; Schrems, Karol K.; Hawk, Jeffrey A.; Druschitz, A.P. (Intermet Corp., Lynchburg, VA)

    2001-10-01T23:59:59.000Z

    The automotive industry is seeking to replace current car parts made of aluminum and iron castings with thin wall (down to 2 mm) iron castings to reduce the cost and weight of automobiles. The mechanical properties of thin wall ductile iron castings are affected strongly by the thickness of the castings. The thinner castings cool at a faster rate, and microstructural features that form during solidification, and subsequently, transform in the solid state, are strongly dependent on a geometrical parameter related to the ratio of surface area-to-volume of the casting. As this ratio becomes larger, castings cool faster. As a result, the nodule count on the observation plane of the specimens increases dramatically (>2000 nodules/mm2 in most specimens), i.e. as the thickness of castings decreases. Also, the matrix of the thin walled ductile iron castings becomes more ferritic as the ratio of surface area-to-volume decreases.

  8. Predicting Pattern Tooling and Casting Dimensions for Investment Casting - Phase II

    SciTech Connect (OSTI)

    Sabau, Adrian S [ORNL

    2005-09-01T23:59:59.000Z

    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.

  9. Nonintrusive sensing and control for intelligent processing and design of castings

    SciTech Connect (OSTI)

    Kunerth, D.C.; Gray, J.

    1995-11-01T23:59:59.000Z

    Two technologies, laser ultrasonics (LUT) for detecting inclusions in liquid metals and x-ray stereography (XS) for detecting and locating porosity and inclusions in castings, were evaluated. LUT is a relatively new technology that has the potential to operate in the harsh environment of metal melting, without melt contamination, because of its noncontacting nature. It was shown that LUT can detect and monitor inclusions in liquid metal, but limitations exist that restrict its implementation as well as minimize the advantage gained from its noncontacting nature. In many applications it is acceptable for castings to have a limited amount of inclusions or porosity if these are not in a critical location. XS can determine the physical location of defects and, when integrated into a real-time radiographic system, is useful for quickly evaluating the quality of castings prior to adding value via finish steps. It was demonstrated that XS can achieve a location accuracy of 0.2 mm relative to a part surface and can be configured as an inexpensive add-on to existing real-time systems.

  10. Deformation Behavior of Nanoporous Metals

    SciTech Connect (OSTI)

    Biener, J; Hodge, A M; Hamza, A V

    2007-11-28T23:59:59.000Z

    Nanoporous open-cell foams are a rapidly growing class of high-porosity materials (porosity {ge} 70%). The research in this field is driven by the desire to create functional materials with unique physical, chemical and mechanical properties where the material properties emerge from both morphology and the material itself. An example is the development of nanoporous metallic materials for photonic and plasmonic applications which has recently attracted much interest. The general strategy is to take advantage of various size effects to introduce novel properties. These size effects arise from confinement of the material by pores and ligaments, and can range from electromagnetic resonances to length scale effects in plasticity. In this chapter we will focus on the mechanical properties of low density nanoporous metals and how these properties are affected by length scale effects and bonding characteristics. A thorough understanding of the mechanical behavior will open the door to further improve and fine-tune the mechanical properties of these sometimes very delicate materials, and thus will be crucial for integrating nanoporous metals into products. Cellular solids with pore sizes above 1 micron have been the subject of intense research for many years, and various scaling relations describing the mechanical properties have been developed.[4] In general, it has been found that the most important parameter in controlling their mechanical properties is the relative density, that is, the density of the foam divided by that of solid from which the foam is made. Other factors include the mechanical properties of the solid material and the foam morphology such as ligament shape and connectivity. The characteristic internal length scale of the structure as determined by pores and ligaments, on the other hand, usually has only little effect on the mechanical properties. This changes at the submicron length scale where the surface-to-volume ratio becomes large and the effect of free surfaces can no longer be neglected. As the material becomes more and more constraint by the presence of free surfaces, length scale effects on plasticity become more and more important and bulk properties can no longer be used to describe the material properties. Even the elastic properties may be affected as the reduced coordination of surface atoms and the concomitant redistribution of electrons may soften or stiffen the material. If, and to what extend, such length scale effects control the mechanical behavior of nanoporous materials depends strongly on the material and the characteristic length scale associated with its plastic deformation. For example, ductile materials such as metals which deform via dislocation-mediated processes can be expected to exhibit pronounced length scale effects in the sub-micron regime where free surfaces start to constrain efficient dislocation multiplication. In this chapter we will limit our discussion to our own area of expertise which is the mechanical behavior of nanoporous open-cell gold foams as a typical example of nanoporous metal foams. Throughout this chapter we will review our current understanding of the mechanical properties of nanoporous open-cell foams including both experimental and theoretical studies.

  11. Self-Similar Collapse of Stationary Bulk Foams Tad W. Patzek

    E-Print Network [OSTI]

    Patzek, Tadeusz W.

    flotation (Sutherland and Clark, 1955). Foam barriers might also be used to control gas mi- gration again. Preformed drilling foams are used to lift crushed rock, sand or mud, and their lifetimes

  12. Control of Vapor Dispersion and Pool Fire of Liquefied Natural Gas (LNG) with Expansion Foam

    E-Print Network [OSTI]

    Yun, Geun Woong

    2011-10-21T23:59:59.000Z

    in outdoor field tests. Thus, this research focused on experimental determination of the effect of expansion foam application on LNG vapor dispersion and pool fire. Specifically, for evaluating the use of foam to control the vapor hazard from spilled LNG...

  13. Alkali corrosion resistant coatings and ceramic foams having superfine open cell structure and method of processing

    DOE Patents [OSTI]

    Brown, Jr., Jesse J. (Christiansburg, VA); Hirschfeld, Deidre A. (Elliston, VA); Li, Tingkai (Blacksburg, VA)

    1993-12-07T23:59:59.000Z

    Alkali corrosion resistant coatings and ceramic foams having superfine open cell structure are created using sol-gel processes. The processes have particular application in creating calcium magnesium zirconium phosphate, CMZP, coatings and foams.

  14. 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

    2011-06-01T23:59:59.000Z

    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.

  15. The Effect of Moisture Absorption on the Physical Properties of Polyurethane Shape Memory Polymer Foams

    E-Print Network [OSTI]

    Yu, Ya-Jen

    2012-07-16T23:59:59.000Z

    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...

  16. 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)

    2002-09-17T23:59:59.000Z

    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).

  17. Carbon or graphite foam as a heating element and system thereof

    DOE Patents [OSTI]

    Ott, Ronald D. (Knoxville, TN) [Knoxville, TN; McMillan, April D. (Knoxville, TN) [Knoxville, TN; Choudhury, Ashok (Oak Ridge, TN) [Oak Ridge, TN

    2004-05-04T23:59:59.000Z

    A temperature regulator includes at least one electrically conductive carbon foam element. The foam element includes at least two locations adapted for receiving electrical connectors thereto for heating a fluid, such as engine oil. A combustion engine includes an engine block and at least one carbon foam element, the foam element extending into the engine block or disposed in thermal contact with at least one engine fluid.

  18. Collapse mechanisms of sandwich beams with composite faces and a foam core,

    E-Print Network [OSTI]

    Fleck, Norman A.

    - strated for aluminium alloy face sheets and polymeric foam cores, it has since been extended to other

  19. Redox reaction and foaming in nuclear waste glass melting

    SciTech Connect (OSTI)

    Ryan, J.L.

    1995-08-01T23:59:59.000Z

    This document was prepared by Pacific Northwest Laboratory (PNL) and is an attempt to analyze and estimate the effects of feed composition variables and reducing agent variables on the expected chemistry of reactions occurring in the cold cap and in the glass melt in the nuclear waste glass Slurry-fed, joule-heated melters as they might affect foaming during the glass-making process. Numerous redox reactions of waste glass components and potential feed additives, and the effects of other feed variables on these reactions are reviewed with regard to their potential effect on glass foaming. A major emphasis of this report is to examine the potential positive or negative aspects of adjusting feed with formic acid as opposed to other feed modification techniques including but not limited to use of other reducing agents. Feed modification techniques other than the use of reductants that should influence foaming behavior include control of glass melter feed pH through use of nitric acid. They also include partial replacement of sodium salts by lithium salts. This latter action (b) apparently lowers glass viscosity and raises surface tension. This replacement should decrease foaming by decreasing foam stability.

  20. Search for solar chameleons and relic axions with CAST

    E-Print Network [OSTI]

    Cantatore, G; Zioutas, K

    2015-01-01T23:59:59.000Z

    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

  1. aqueous tape casting: Topics by E-print Network

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

    K; Zioutas, Konstantin; 10.1103PhysRevLett.94.121301 2005-01-01 397 The CERN Axion Solar Telescope (CAST): status and prospects Astrophysics (arXiv) Summary: The CAST...

  2. aged cast stainless: Topics by E-print Network

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

    K; Zioutas, Konstantin; 10.1103PhysRevLett.94.121301 2005-01-01 339 The CERN Axion Solar Telescope (CAST): status and prospects Astrophysics (arXiv) Summary: The CAST...

  3. Magnesium Replacement of Aluminum Cast Components in a Production...

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

    Replacement of Aluminum Cast Components in a Production V6 Engine to Effect Cost-Effective Mass Reduction Magnesium Replacement of Aluminum Cast Components in a Production V6...

  4. Shape memory poly(3-caprolactone)-co-poly(ethylene glycol) foams with body temperature triggering and

    E-Print Network [OSTI]

    Mather, Patrick T.

    Shape memory poly(3-caprolactone)-co-poly(ethylene glycol) foams with body temperature triggering the fabrication of porous foams with shape memory triggering at body temperature. Employing a modified porogen are crosslinked via thiol≠ene chemistry to generate highly porous foam scaffolds with shape memory capacity

  5. Foam Control using a Fluidized Bed of Hydrophobic Particles by Clara Mata*

    E-Print Network [OSTI]

    Joseph, Daniel D.

    Applications of foams and foaming are found in many industries like the flotation of minerals, enhanced oil recovery, drilling in oil reservoirs, insulation, construction and refining processes such as Vacuum and foaming are found in many industries like the flotation of minerals, enhanced oil recovery, drilling

  6. Composites: Part B 44 (2013) 584591 584 Tensile Properties of Carbon Nanofiber Reinforced Multiscale Syntactic Foams

    E-Print Network [OSTI]

    Gupta, Nikhil

    The mechanical behavior of hollow glass microballoon-epoxy matrix syntactic foams reinforced with carbon compositions of syntactic foams, epoxy resins filled with glass microballoons are widely studied due to the extensive use of epoxy resins in aerospace applications [5-7]. Studies on these glass/epoxy syntactic foams

  7. 1Cellular Polymers, Vol. 26, No. 1, 2007 On the Bulk Modulus of Open Cell Foams

    E-Print Network [OSTI]

    Lakes, Roderic

    Hydrostaticcompressionoffoamisofinterestinavarietyofcontextsincluding under-sea applications. Syntactic foam, for instance, consists of hollow glass1Cellular Polymers, Vol. 26, No. 1, 2007 On the Bulk Modulus of Open Cell Foams © Rapra Technology, 2007 On the Bulk Modulus of Open Cell Foams B. Moore, T. Jaglinski, D.S. Stone§ and R.S. Lakes

  8. 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 depend, to a large extent, on foams formed on the surface of the molten glass and of the batch due models for thermophysical and transport properties and heat, mass, and radiation transfer in glass foams

  9. Sedimenting discs in a two-dimensional foam I. T. Davies, S. J. Cox

    E-Print Network [OSTI]

    Cox, Simon

    -dimensional foams can be thought of as a monolayer of bubbles squeezed between two glass plates. We choose to probeSedimenting discs in a two-dimensional foam I. T. Davies, S. J. Cox Institute of Mathematics in a dry two-dimensional, monodisperse foam is studied. This, a variation of the classical Stokes

  10. Experimental characterization and numerical simulations of a syntactic-foam/glass-bre composite sandwich

    E-Print Network [OSTI]

    Corigliano, Alberto

    Experimental characterization and numerical simulations of a syntactic-foam/glass-¬ģbre composite core. Such core consists of a syntactic foam made by hollow glass microspheres embedded in an epoxy. Keywords: A. Glass ¬ģbre; Composite sandwich; Syntactic foam; Mechanical tests; Numerical simulations (FE) 1

  11. Plateau border bulimia transition: discontinuities expected in three simple experiments on 2D liquid foams

    E-Print Network [OSTI]

    Paris-Sud XI, Université de

    be observable. II. 2D GLASS-GLASS FOAM GEOMETRICAL VADEMECUM In the present section, we shall provide a geometri- cal description and some corresponding results for two- dimensional foams squeezed between two glass liquid foams Pierre Rognon, Fran¬łcois Molino, and Cyprien Gay Centre de Recherche Paul Pascal, CNRS, UPR

  12. Plateau border bulimia transition: discontinuities expected in three simple experiments on 2D liquid foams

    E-Print Network [OSTI]

    Recanati, Catherine

    be observable. II. 2D GLASS-GLASS FOAM GEOMETRICAL VADEMECUM In the present section, we shall provide a geometri- cal description and some corresponding results for two- dimensional foams squeezed between two glass liquid foams Pierre Rognon, Fran#24;cois Molino, and Cyprien Gay #3; Centre de Recherche Paul Pascal

  13. Solidification of Aluminum Alloys Edited by TMS (The Minerals, Metals & Materials Society), 2004

    E-Print Network [OSTI]

    Zabaras, Nicholas J.

    Solidification of Aluminum Alloys Edited by TMS (The Minerals, Metals & Materials Society), 2004 Modeling the Effects of Mold Topography on Aluminum Cast Surfaces Lijian Tan1 , Nicholas Zabaras1 1 14853, USA Keywords: Aluminum Solidification; Mold topography; Cast Surfaces Abstract The air

  14. Thermal resistance of composite panels containing superinsulation and urethane foam

    SciTech Connect (OSTI)

    Wilkes, K.E.; Graves, R.S.; Childs, K.W.

    1996-09-01T23:59:59.000Z

    Laboratory data are presented on the thermal resistance of composite panels that incorporate superinsulation embedded in urethane foam. Composite panels were fabricated using four types of advanced insulations (three types of evacuated panel superinsulation and one type of gas-filled panel), and three foam blowing agents (CFC-11, HCFC-141b, and HCFC-142b/22 blend). Panels were also fabricated with only the urethane foam to serve as a baseline. Thermal measurements were performed using an ASTM C 518 Heat Flow Meter Apparatus. The thermal resistances of the panels were measured over a two-year period to detect whether any significant changes occurred. A computer model was used to analyze the data, adjusting for differences in size of the advanced insulations, and extrapolating to different sizes of composite panels.

  15. Thermal resistance of superinsulation/foam composite panels

    SciTech Connect (OSTI)

    Wilkes, K.E.; Graves, R.S.; Childs, K.W.

    1996-05-01T23:59:59.000Z

    Laboratory data are presented on the thermal resistance of composite panels that incorporate superinsulation embedded in urethane foam. Composite panels were fabricated using four types of advanced insulations (three types of evacuated panel superinsulation and one type of gas-filled panel), and three foam blowing agents (CFC-11, HCFC-141b, and HCFC-142b/22 blend). Panels were also fabricated with only the urethane foam to serve as a baseline. Thermal measurements were performed using an ASTM C 518 Heat Flow Meter Apparatus. The thermal resistances of the panels were measured over a two-year period to detect whether any significant changes occurred. A computer model was used to analyze the data, normalizing for differences in size of the advanced insulations, and extrapolating to different sizes of composite panels.

  16. Ultra-low density microcellular polymer foam and method

    DOE Patents [OSTI]

    Simandl, R.F.; Brown, J.D.

    1996-03-19T23:59:59.000Z

    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.

  17. Ultra-low density microcellular polymer foam and method

    DOE Patents [OSTI]

    Simandl, Ronald F. (Farragut, TN); Brown, John D. (Harriman, TN)

    1996-01-01T23:59:59.000Z

    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.

  18. Method for epoxy foam production using a liquid anhydride

    DOE Patents [OSTI]

    Celina, Mathias (Albuquerque, NM)

    2012-06-05T23:59:59.000Z

    An epoxy resin mixture with at least one epoxy resin of between approximately 50 wt % and 100 wt %, an anhydride cure agent of between approximately 0 wt % and approximately 50 wt %, a tert-butoxycarbonyl anhydride foaming agent of between proximately 0.1-20 wt %, a surfactant and an imidazole or similar catalyst of less than approximately 2 wt %, where the resin mixture is formed from at least one epoxy resin with a 1-10 wt % tert-butoxycarbonyl anhydride compound and an imidazole catalyst at a temperature sufficient to keep the resin in a suitable viscosity range, the resin mixture reacting to form a foaming resin which in the presence of an epoxy curative can then be cured at a temperature greater than 50.degree. C. to form an epoxy foam.

  19. Modeling epoxy foams exposed to fire-like heat fluxes.

    SciTech Connect (OSTI)

    Hobbs, Michael L.

    2004-11-01T23:59:59.000Z

    A decomposition chemistry and heat transfer model to predict the response of removable epoxy foam (REF) exposed to fire-like heat fluxes is described. The epoxy foam was created using a perfluorohexane blowing agent with a surfactant. The model includes desorption of the blowing agent and surfactant, thermal degradation of the epoxy polymer, polymer fragment transport, and vapor-liquid equilibrium. An effective thermal conductivity model describes changes in thermal conductivity with reaction extent. Pressurization is modeled assuming: (1) no strain in the condensed-phase, (2) no resistance to gas-phase transport, (3) spatially uniform stress fields, and (4) no mass loss from the system due to venting. The model has been used to predict mass loss, pressure rise, and decomposition front locations for various small-scale and large-scale experiments performed by others. The framework of the model is suitable for polymeric foams with absorbed gases.

  20. Modeling epoxy foams exposed to fire-like heat fluxes.

    SciTech Connect (OSTI)

    Hobbs, Michael L.

    2004-10-01T23:59:59.000Z

    A decomposition chemistry and heat transfer model to predict the response of removable epoxy foam (REF) exposed to fire-like heat fluxes is described. The epoxy foam was created using a perfluorohexane blowing agent with a surfactant. The model includes desorption of the blowing agent and surfactant, thermal degradation of the epoxy polymer, polymer fragment transport, and vapor-liquid equilibrium. An effective thermal conductivity model describes changes in thermal conductivity with reaction extent. Pressurization is modeled assuming: (1) no strain in the condensed-phase, (2) no resistance to gas-phase transport, (3) spatially uniform stress fields, and (4) no mass loss from the system due to venting. The model has been used to predict mass loss, pressure rise, and decomposition front locations for various small-scale and large-scale experiments performed by others. The framework of the model is suitable for polymeric foams with absorbed gases.

  1. Gelcasting Alumina Cores for Investment Casting

    SciTech Connect (OSTI)

    Janney, M A; Klug, F J

    2001-01-01T23:59:59.000Z

    General Electric currently uses silica investment casting cores for making superalloy turbine blades. The silica core technology does not provide the degree of dimensional control needed for advanced turbine system manufacture. The sum of the various process variables in silica core manufacturing produces cores that have more variability than is allowed for in advanced, power-generation gas turbine airfoils.

  2. Cast Stainless Steel Ferrite and Grain Structure

    SciTech Connect (OSTI)

    Ruud, Clayton O.; Ramuhalli, Pradeep; Meyer, Ryan M.; Mathews, Royce; Diaz, Aaron A.; Anderson, Michael T.

    2012-09-01T23:59:59.000Z

    In-service inspection requirements dictate that piping welds in the primary pressure boundary of light-water reactors be subject to a volumetric examination based on the rules contained within the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section XI. The purpose of the inspection is the reliable detection and accurate sizing of service-induced degradation and/or material flaws introduced during fabrication. The volumetric inspection is usually carried out using ultrasonic testing (UT) methods. However, the varied metallurgical macrostructures and microstructures of cast austenitic stainless steel piping and fittings, including statically cast stainless steel and centrifugally cast stainless steel (CCSS), introduce significant variations in the propagation and attenuation of ultrasonic energy. These variations complicate interpretation of the UT responses and may compromise the reliability of UT inspection. A review of the literature indicated that a correlation may exist between the microstructure and the delta ferrite content of the casting alloy. This paper discusses the results of a recent study where the goal was to determine if a correlation existed between measured and/or calculated ferrite content and grain structure in CCSS pipe.

  3. Continuous Casting Consortium Report to POSCO

    E-Print Network [OSTI]

    Thomas, Brian G.

    in Fig. 2, the gas fuel (such as propane C3H8) and oxygen leaving the torch combust into a high of the heat is transported away through radiation and advection with the combustion gas and the rest- 1 - Continuous Casting Consortium Report to POSCO Modeling Steel Slab Heat Transfer During

  4. Foaming and Antifoaming in Radioactive Waste Pretreatment and Immobilization Processes

    SciTech Connect (OSTI)

    Darsh T. Wasan; Alex D. Nikolov; D.P. Lamber; T. Bond Calloway; M.E. Stone

    2005-03-12T23:59:59.000Z

    Savannah River National Laboratory (SRNL) has reported severe foaminess in the bench scale evaporation of the Hanford River Protection - Waste Treatment Plant (RPP-WPT) envelope C waste. Excessive foaming in waste evaporators can cause carryover of radionuclides and non-radioactive waste to the condensate system. The antifoams used at Hanford and tested by SRNL are believed to degrade and become inactive in high pH solutions. Hanford wastes have been known to foam during evaporation causing excessive down time and processing delays.

  5. Coarse graining methods for spin net and spin foam models

    E-Print Network [OSTI]

    Bianca Dittrich; Frank C. Eckert; Mercedes Martin-Benito

    2011-09-22T23:59:59.000Z

    We undertake first steps in making a class of discrete models of quantum gravity, spin foams, accessible to a large scale analysis by numerical and computational methods. In particular, we apply Migdal-Kadanoff and Tensor Network Renormalization schemes to spin net and spin foam models based on finite Abelian groups and introduce `cutoff models' to probe the fate of gauge symmetries under various such approximated renormalization group flows. For the Tensor Network Renormalization analysis, a new Gauss constraint preserving algorithm is introduced to improve numerical stability and aid physical interpretation. We also describe the fixed point structure and establish an equivalence of certain models.

  6. Humidifier for fuel cell using high conductivity carbon foam

    DOE Patents [OSTI]

    Klett, James W.; Stinton, David P.

    2006-12-12T23:59:59.000Z

    A method and apparatus of supplying humid air to a fuel cell is disclosed. The extremely high thermal conductivity of some graphite foams lends itself to enhance significantly the ability to humidify supply air for a fuel cell. By utilizing a high conductivity pitch-derived graphite foam, thermal conductivity being as high as 187 W/m.dot.K, the heat from the heat source is more efficiently transferred to the water for evaporation, thus the system does not cool significantly due to the evaporation of the water and, consequently, the air reaches a higher humidity ratio.

  7. Synthesis and casting of a lithium-bismuth compound for an ion-replacement electrorefiner.

    SciTech Connect (OSTI)

    McDeavitt, S. M.

    1998-11-23T23:59:59.000Z

    The intermetallic compound Li{sub 3}Bi played an integral part in the demonstration of an ion replacement electrorefining method developed at Argonne National Laboratory. The Li{sub 3}Bi compound was generated in a tilt-pour casting furnace using high-purity lithium and bismuth metals as the initial charge. At first, small-scale ({approximately}20 g) experiments were conducted to determine the materials synthesis parameters. In the end, four larger-scale castings (500 g to 1250 g) were completed in a tantalum crucible. The metals were heated slowly to melt the charge, and the formation reaction proceeded vigorously above the melting point of bismuth ({approximately}270 C). For the large-scale melts, the furnace power was temporarily turned off at this point. After several minutes, the tantalum crucible stopped glowing, and the furnace power was turned on. The temperature was then increased to {approximately}1200 C to melt and homogenize the compound, and liquid Li{sub 3}Bi was cast into cold stainless steel molds. Approximately 3.7 kg of Li{sub 3}Bi was generated by this method.

  8. Toxicology evaluation and hazard review for non-CFC containing rigid foams BKC 44317 and last-a-foam MSL-02A

    SciTech Connect (OSTI)

    Greulich, K.A.; Archuleta, M.M.

    1996-06-01T23:59:59.000Z

    New pour-in-place, low density, rigid polyurethane foam kits have been developed to mechanically stabilize damaged explosive ordnance. Although earlier foam systems used chlorofluorocarbons as blowing agents, the current versions rely on carbon dioxide generated by the reaction of isocynates with water. In addition, these kits were developed to manually generate small quantifies of rigid foam in the field with minimal or no protective equipment. The purpose of this study was to evaluate and summarize available hazard information for the components of these rigid foam kits and to provide recommendations for personal protective equipment to be used while performing the manual combination of the components. As with most rigid foam systems, these kits consist of two parts, one a mixture of isocyanates; the other, a combination of polyols, surfactants, and amine catalysts. Once completely deployed, the rigid foam is non-toxic. The components, however, have some important health effects which must be considered when establishing handling procedures.

  9. 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. [Eck Industreis, Inc.] [Eck Industreis, Inc.; Gegal, Gerald A.

    2014-04-15T23:59:59.000Z

    The objective of this project was to provide a production capable cast aluminum metal matrix composite (MMC) alloy with an operating temperature capability of 250-300įC. Important industrial sectors as well as the military now seek lightweight aluminum alloy castings that can operate in temperature ranges of 250-300įC. 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.

  10. Environmentally-benign Flame Retardant Nanocoating for Foam and Fabric†

    E-Print Network [OSTI]

    Cain, Amanda Ashley

    2014-12-09T23:59:59.000Z

    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...

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

    E-Print Network [OSTI]

    Kilpatrick, Peter K.

    Factors Contributing to Petroleum Foaming. 1. Crude Oil Systems Michael K. Poindexter,*, Nael N production, producers often determine beforehand various processing issues that might be encountered during full-scale production. A host of issues are considered pertinent, some of which include production line

  12. Cometabolic Degradation of TCE Vapors in a Foamed Emulsion

    E-Print Network [OSTI]

    Cometabolic Degradation of TCE Vapors in a Foamed Emulsion Bioreactor E U N S U N G K A N A N D M the experiments, 85-101% of the degraded TCE chlorine was recovered as chloride. Overall, the results suggest to complete degradation of TCE to harmless end products. Unfortunately, no microorganism can grow on TCE

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

    E-Print Network [OSTI]

    Patzek, Tadeusz W.

    -scale simulation is a vital component of the engineering and economic evaluation of any enhanced oil recovery (EOR Copyright 1997, Society of Petroleum Engineers, Inc. Received for review, April 24, 1997 Revised, July 23 generation, and foam propagation in rock formations. Efficient application and evaluation of candidates

  14. 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

  15. Solar axion search with the CAST experiment

    E-Print Network [OSTI]

    CAST Collaboration; E. Arik; S. Aune; D. Autiero; K. Barth; A. Belov; B. BeltrŠn; S. Borghi; F. S. Boydag; H. Bršuninger; 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. GalŠn; E. Gazis; T. Geralis; I. Giomataris; S. Gninenko; H. Gůmez; 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. KŲnigsmann; R. Kotthaus; M. Kr?mar; K. Kousouris; M. Kuster; B. Laki?; C. Lasseur; A. Liolios; A. Ljubi?i?; V. Lozza; G. Lutz; G. Luzůn; D. Miller; J. Morales; T. Niinikoski; A. Nordt; A. Ortiz; T. Papaevangelou; M. J. Pivovaroff; A. Placci; G. Raiteri; G. Raffelt; H. Riege; A. RodrŪguez; 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

    2008-10-10T23:59:59.000Z

    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.

  16. Phase Transformation in Cast Superaustenitic Stainless Steels

    SciTech Connect (OSTI)

    Nathaniel Steven Lee Phillips

    2006-12-12T23:59:59.000Z

    Superaustenitic stainless steels constitute a group of Fe-based alloys that are compositionally balanced to have a purely austenitic matrix and exhibit favorable pitting and crevice corrosion resistant properties and mechanical strength. However, intermetallic precipitates such as sigma and Laves can form during casting or exposure to high-temperature processing, which degrade the corrosion and mechanical properties of the material. The goal of this study was to accurately characterize the solid-solid phase transformations seen in cast superaustenitic stainless steels. Heat treatments were performed to understand the time and temperature ranges for intermetallic phase formations in alloys CN3MN and CK3MCuN. Microstructures were characterized using scanning electron microscopy (SEM), transmission electron microscopy (TEM), and energy and wavelength dispersive spectroscopy (EDS, WDS). The equilibrium microstructures, composed primarily of sigma and Laves within purely austenitic matrices, showed slow transformation kinetics. Factors that determine the extent of transformation, including diffusion, nucleation, and growth, are discussed.

  17. 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)

    2002-01-01T23:59:59.000Z

    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.

  18. Note and calculations concerning elastic dilatancy in 2D glass-glass liquid foams Francois Molino, Pierre Rognon, and Cyprien Gay

    E-Print Network [OSTI]

    Paris-Sud XI, Université de

    Note and calculations concerning elastic dilatancy in 2D glass-glass liquid foams Fran¬łcois Molino 30, 2010) When deformed, liquid foams tend to raise their liquid contents like immersed granular dilatancy in 3D foams and in very dry foams squeezed between two solid plates (2D GG foams). Here, we

  19. Thin Wall Cast Iron: Phase II

    SciTech Connect (OSTI)

    Doru M. Stefanescu

    2005-07-21T23:59:59.000Z

    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.

  20. CAST: An Inspiring Axion Helioscope ala Sikivie

    SciTech Connect (OSTI)

    Zioutas, K.; Anastassopoulos, V. [University of Patras, Patras (Greece); Tsagri, M. [University of Patras, Patras (Greece); CERN, 1211 Geneve 23 (Switzerland); Semertzidis, Y. [Brookhaven National Laboratory, Upton, NY (United States); Papaevangelou, T. [IRFU, Centre d'Etudes Nucleaires de Saclay, Gif-sur-Yvette (France)

    2010-08-30T23:59:59.000Z

    CAST is a data taking axion helioscope using a recycled LHC test magnet, CERN's detector technology and cryogenics expertise. An imaging X-ray telescope improves substantially the detection sensitivity and axion-ID. Massive axion-like particles of the Kaluza-Klein type were first introduced to explain the paradox of the hot corona, which is even hotter at locations overlying magnetic spots. This is suggesting that the CAST detection principle might be at work there, but being somehow modified and performing better. Remarkably, the density profile of the Sun allows for resonance crossing (m{sub axion}c{sup 2{approx_equal}}h{omega}{sub plasma}), which axion helioscopes are aiming to reach. The restless Sun favours this occasionally even further. Then, such processes can give rise to a chimera of converted axions or the like, making the Sun appear, within known physics, as mysterious and unpredictable as it is. CAST axion limits were used to conclude also for the hidden sector paraphotons. This is then suggestive for novel helioscopes for exotica like paraphotons, chameleons, etc. Pierre Sikivie's pioneering idea was to use a magnetic field as a catalyst to transform particles from the dark sector to ours, and vice versa.

  1. 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)

    1989-01-01T23:59:59.000Z

    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. 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.

    1989-08-01T23:59:59.000Z

    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.

  3. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

    Fox, K. M.; Roberts, K. A.; Edwards, T. B.

    2014-02-28T23:59:59.000Z

    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

  4. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

    Fox, K. M.; Roberts, K. A.; Edwards, T. B.

    2013-09-17T23:59:59.000Z

    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

  5. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

    Fox, K. M.; Edwards, T. A.; Roberts, K. B.

    2013-10-02T23:59:59.000Z

    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

  6. 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

    2010-01-01T23:59:59.000Z

    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).

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

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

    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 methods for...

  8. Ultra Large Castings for Lightweight Vehicle Structures ?AMD...

    Energy Savers [EERE]

    DOE Office of Vehicle Technologies "Mega" Merit Review 2008 on February 25, 2008 in Bethesda, Maryland. merit08mccarty6.pdf More Documents & Publications Ultra Large Castings...

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

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

    properties, the high cost of materials, and an increased susceptibility to galvanic corrosion. This project aims to develop an integrated die casting (IDC) process that will...

  10. The Effect of Applied Pressure During Feeding of Critical Cast Aluminum Alloy Components With Particular Reference to Fatigue Resistance

    SciTech Connect (OSTI)

    J.T. Berry; R. Luck; B. Zhang; R.P. Taylor

    2003-06-30T23:59:59.000Z

    the medium to long freezing range alloys of aluminum such as A356, A357, A206, 319 for example are known to exhibit dispersed porosity, which is recognized as a factor affecting ductility, fracture toughness, and fatigue resistance of light alloy castings. The local thermal environment, for example, temperature gradient and freezing from velocity, affect the mode of solidification which, along with alloy composition, heat treatment, oxide film occlusion, hydrogen content, and the extent to which the alloy contracts on solidification, combine to exert strong effects on the porosity formation in such alloys. In addition to such factors, the availability of liquid metal and its ability to flow through the partially solidified casting, which will be affect by the pressure in the liquid metal, must also be considered. The supply of molten metal will thus be controlled by the volume of the riser available for feeding the particular casting location, its solidification time, and its location together with any external pressure that might be applied at the riser.

  11. CO/sub 2/ foam flooding performance vs. rock wettability

    SciTech Connect (OSTI)

    Lescure, B.M.; Claridge, E.L.

    1986-01-01T23:59:59.000Z

    CO/sub 2/ flooding projects have shown large potential for oil recovery, but in many cases the volumetric sweep efficiency is greatly limited by gravity tonguing and/or viscous fingering. To reduce these effects foam could be used as an alternative to WAG CO/sub 2/ injection. Experiments on the CO/sub 2/ foam process were conducted in a 1/4 5-spot reservoir model in order to investigate the effect of rock wetting state and total CO/sub 2/ slug size on secondary and tertiary extra-oil recovery. Laboratory model results show that the process is more successful in an oil-wet medium than in a water-wet medium due to larger surfactant adsorption in the water-wet medium. Also, requirements for optimal CO/sub 2/ slug size are smaller than in the WAG process, with larger extra oil recovery for both secondary and tertiary floods.

  12. Calibrating the Abaqus Crushable Foam Material Model using UNM Data

    SciTech Connect (OSTI)

    Schembri, Philip E. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Lewis, Matthew W. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2014-02-27T23:59:59.000Z

    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.

  13. Effects of quantum space time foam in the neutrino sector

    E-Print Network [OSTI]

    H. V. Klapdor-Kleingrothaus; H. Pšs; U. Sarkar

    2000-07-05T23:59:59.000Z

    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.

  14. Equipment compatibility and logistics assessment for containment foam deployment.

    SciTech Connect (OSTI)

    McRoberts, Vincent M.; Martell, Mary-Alena; Jones, Joseph A.

    2005-09-01T23:59:59.000Z

    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.

  15. Production of High Quality Dust Control Foam to Minimize Moisture Addition to Coal

    E-Print Network [OSTI]

    Termine, F.; Jordan, S. T.

    PRODUCTION OF HIGH QUALITY DUST CONTROL FOAM TO MINIMIZE MOISTURE ADDITION TO COAL Frank Tenni ne Steve T. Jordan BETZ Laboratories, Trevose, PA Inc. ABSTRACT Foam is displacing wet suppression as the method of choice for controlling... fugitive emissions from coal. Coal treated by wet suppression consumes through moisture addition, a heat energy equivalent of 1 ton out of every 500 tons fired. The application of foam requires less than 10% of the moisture usually required for wet...

  16. Apparatus And Method For Producing Single Crystal Metallic Objects

    DOE Patents [OSTI]

    Huang, Shyh-Chin (Latham, NY); Gigliotti, Jr., Michael Francis X. (Scotia, NY); Rutkowski, Stephen Francis (Duanesburg, NY); Petterson, Roger John (Fultonville, NY); Svec, Paul Steven (Scotia, NY)

    2006-03-14T23:59:59.000Z

    A mold is provided for enabling casting of single crystal metallic articles including a part-defining cavity, a sorter passage positioned vertically beneath and in fluid communication with the part-defining cavity, and a seed cavity positioned vertically beneath and in fluid communication with the sorter passage. The sorter passage includes a shape suitable for encouraging a single crystal structure in solidifying molten metal. Additionally, a portion of the mold between the sorter passage and the part-defining cavity includes a notch for facilitating breakage of a cast article proximate the notch during thermal stress build-up, so as to prevent mold breakage or the inclusion of part defects.

  17. Comments on Cahill's Quantum Foam Inflow Theory of Gravity

    E-Print Network [OSTI]

    T. D. Martin

    2004-07-20T23:59:59.000Z

    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.

  18. SmartCast - Novel Textile Sensors for Embedded Pressure Sensing of Orthopedic Casts

    E-Print Network [OSTI]

    Danilovic, Andrew

    2013-01-01T23:59:59.000Z

    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

  19. Continuation of Crosscutting Technology Development at Cast

    SciTech Connect (OSTI)

    Yoon, Roe-Hoan

    2012-03-31T23:59:59.000Z

    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

    2004-12-19T23:59:59.000Z

    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.

  1. Pitch-based carbon foam heat sink with phase change material

    DOE Patents [OSTI]

    Klett, James W. (Knoxville, TN); Burchell, Timothy D. (Oak Ridge, TN)

    2002-01-01T23:59:59.000Z

    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.

  2. Pitch-based carbon foam heat sink with phase change material

    DOE Patents [OSTI]

    Klett, James W. (Knoxville, TN); Burchell, Timothy D. (Oak Ridge, TN)

    2000-01-01T23:59:59.000Z

    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.

  3. 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

  4. Pitch-based carbon foam heat sink with phase change material

    DOE Patents [OSTI]

    Klett, James W.; Burchell, Timothy D.

    2007-01-02T23:59:59.000Z

    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.

  5. Pitch-based carbon foam heat sink with phase change material

    DOE Patents [OSTI]

    Klett, James W.; Burchell, Timothy D.

    2007-01-23T23:59:59.000Z

    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.

  6. Pitch-based carbon foam heat sink with phase change material

    DOE Patents [OSTI]

    Klett, James W.; Burchell, Timothy D.

    2004-08-24T23:59:59.000Z

    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.

  7. Pitch-based carbon foam heat sink with phase change material

    DOE Patents [OSTI]

    Klett, James W.; Burchell, Timothy D.

    2006-03-21T23:59:59.000Z

    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.

  8. Area 2: Use Of Engineered Nanoparticle-Stabilized CO 2 Foams...

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

    nanoparticle's surface, nanoparticle concentration, salinity, presence of surfactant, CO2:water ratio, and fluid flow rate are each discussed. This work on NP-CW foam...

  9. The use of coated micropowders to reduce radiation heat transfer in foam insulation

    E-Print Network [OSTI]

    Marge, Arlene Lanciani

    1991-01-01T23:59:59.000Z

    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. ...

  10. 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)

    2010-05-04T23:59:59.000Z

    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.

  11. Stabilization of Electrocatalytic Metal Nanoparticles at Metal...

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

    Electrocatalytic Metal Nanoparticles at Metal-Metal Oxide-Graphene Triple Junction Points. Stabilization of Electrocatalytic Metal Nanoparticles at Metal-Metal Oxide-Graphene...

  12. Apparatus for efficient sidewall containment of molten metal with horizontal alternating magnetic fields utilizing a ferromagnetic dam

    DOE Patents [OSTI]

    Praeg, W.F.

    1997-02-11T23:59:59.000Z

    An apparatus is disclosed for casting sheets of metal from molten metal. The apparatus includes a containment structure having an open side, a horizontal alternating magnetic field generating structure and a ferromagnetic dam. The magnetic field and the ferromagnetic dam contain the molten metal from leaking out side portions of the open side of the containment structure. 25 figs.

  13. Heat Treatment Procedure Qualification for Steel Castings

    SciTech Connect (OSTI)

    Professor Robert C. Voigt

    2003-02-02T23:59:59.000Z

    The science of heat treatment has been well studied and is the basis from which existing specifications and practices for the heat treatment of steel castings have been developed. Although these existing specifications address the general needs of steel castings to be heat-treated, they do not take into account the variability in the parameters that govern the processes. The need for a heat treatment qualification procedure that accounts for this variability during heat treatment is an important step toward heat treatment quality assurance. The variability in temperatures within a heat treatment furnace is one such variable that a foundry has to contend with in its day-to-day activity. Though specifications indicate the temperatures at which a particular heat treatment has to be conducted, heat treatment specifications do not adequately account for all aspects of heat treatment quality assurance. The heat treatment qualification procedure will comprise of a robust set of rules and guidelines that ensure that foundries will still be able to operate within the set of constraints imposed on them by non-deterministic elements within the processes.

  14. Automatic 3D modeling of palatal plaster casts Marco Andreetto

    E-Print Network [OSTI]

    Abu-Mostafa, Yaser S.

    duplicated by 3D printers. A second application where 3D models of palatal casts could also be usefulAutomatic 3D modeling of palatal plaster casts Marco Andreetto Dept. of Information Engineer corte@dei.unipd.it Abstract This work introduces a procedure for automatic 3D model- ing and discusses

  15. Casting Porosity-Free Grain Refined Magnesium Alloys

    SciTech Connect (OSTI)

    Schwam, David [Case Western Reserve University] [Case Western Reserve University

    2013-08-12T23:59:59.000Z

    The objective of this project was to identify the root causes for micro-porosity in magnesium alloy castings and recommend remedies that can be implemented in production. The findings confirm the key role played by utilizing optimal gating and risering practices in minimizing porosity in magnesium castings.?

  16. Solar Cells: Spin-Cast Bulk Heterojunction Solar Cells: A Dynamical...

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

    Solar Cells: Spin-Cast Bulk Heterojunction Solar Cells: A Dynamical Investigation Solar Cells: Spin-Cast Bulk Heterojunction Solar Cells: A Dynamical Investigation Print Wednesday,...

  17. Final Report: Use of Graphite Foam as a Thermal Performance Enhancement of Heavy Hybrid Propulsion Systems

    SciTech Connect (OSTI)

    Klett, James William [ORNL; Conklin, Jim [ORNL

    2011-06-01T23:59:59.000Z

    Oak Ridge National Laboratory's graphite foam has the potential to be used as a heat exchanger for the Army's Future Combat System Manned Ground Vehicle and thus has the potential to improve its thermal performance. The computational fluid dynamics (CFD) program FLOW3D was used to develop a new CFD model for the graphite foam to be used in the development of a proper heat exchanger. The program was calibrated by first measuring the properties of the solid foams and determining the parameters to be used in the CFD model. Then the model was used to predict within 5% error the performance of finned foam heat sinks. In addition, the f factors and j factors commonly used to predict pressure drop and heat transfer were calculated for both the solid and finned structures. There was some evidence that corrugating the foams would yield higher j/f ratios than state of the art heat exchangers, confirming previously measured data. Because the results show that the CFD model was validated, it is recommended that the funding for Phases 2 through 5 be approved for the design of both the finned heat exchanger using tubes and round fin structures and the solid foam design using corrugated foams. It was found that the new CFD model using FLOW3D can predict both solid foam heat transfer and finned foam heat transfer with the validated model parameters. In addition, it was found that the finned foam structures exhibited j/f ratios that indicate that significant heat transfer is occurring within the fin structures due to aerodynamically induced flow, which is not present in solid aluminum fin structures. It is possible that the foam surfaces can act as turbulators that increase heat transfer without affecting pressure drop, like the vortex generators seen in state of the art heat exchangers. These numbers indicate that the foam can be engineered into an excellent heat exchanger. It was also found that corrugating the solid foams would increase the j/f ratio dramatically, allowing the solid foams to compete directly with standard heat exchangers. Although corrugated L1 foam samples have not been produced (attempts are under way), it is possible that their j/f ratio can be even higher than those of the finned structures.

  18. Effects of surfactants on the microstructure of porous ceramic scaffolds fabricated by foaming for bone tissue engineering

    SciTech Connect (OSTI)

    Wang Xi, E-mail: nano-sun@hotmail.com [College of Chemistry and Chemical Engineering, Central South University, Lushan Road South, Changsha, Hunan 410083 (China); Ruan Jianming [State Key Laboratory for Powder Metallurgy, Central South University, Changsha 410083 (China); Chen Qiyuan [College of Chemistry and Chemical Engineering, Central South University, Lushan Road South, Changsha, Hunan 410083 (China)

    2009-06-03T23:59:59.000Z

    A porous scaffold comprising a {beta}-tricalcium phosphate matrix and bioactive glass powders was fabricated by foaming method and the effects of surfactants as foaming agent on microstructure of scaffolds were investigated. Foaming capacity and foam stability of different surfactants in water firstly were carried out to evaluate their foam properties. The porous structure and pore size distribution of the scaffolds were systematically characterized by scanning electron microscopy (SEM) and an optical microscopy connected to an image analyzer. The results showed that the foam stability of surfactant has more remarkable influence on their microstructure such as pore shape, size and interconnectivity than the foaming ability of one. Porous scaffolds fabricated using nonionic surfactant Tween 80 with large foam stability exhibited higher open and total porosities, and fully interconnected porous structure with a pore size of 750-850 {mu}m.

  19. Foaming of E-Glass II (Report for G Plus Project for PPG)

    SciTech Connect (OSTI)

    Kim, Dong-Sang; Portch, Matthew P.; Matyas, Josef; Hrma, Pavel R.; Pilon, Laurent

    2005-09-23T23:59:59.000Z

    In a previous study, the effect of the furnace atmosphere on E glass foaming was investigated with the specific goal to understand the impact of increased water content on foaming in oxy-fired furnaces. The present study extended the previous study and focused on the effect of glass batch chemical composition on E-glass foaming. The present study also included reruns of foam tests performed in a previous study, which resulted in the same trend: the foaming extent increased nearly linearly with the heating rate and no foam was produced when CO2 + 55% H2O atmosphere was introduced at 300įC. It was shown that the lack of foaming in the test with CO2 + 55% H2O atmosphere introduced at 300įC was caused by a loss of sulfate at T <1250įC because of higher water content at the early stages of melting. The tests with new batches in the present study showed that replacing quicklime with limestone tend to decrease foaming, possibly caused by increased sulfate loss during early stages of melting in the batch with limestone. The batches where Na2SO4 was replaced with NaNO3, NaNO3 + CeO2, or CeO2, produced only very limited foaming regardless of the replacing components. As expected, the foaming extent increased as the sulfate content in the batch increased. The results of the present study suggest that foaming can be reduced by using limestone over quicklime and by decreasing the sulfate addition to a minimum required for refining.

  20. Grain Refinement of Permanent Mold Cast Copper Base Alloys

    SciTech Connect (OSTI)

    M.Sadayappan; J.P.Thomson; M.Elboujdaini; G.Ping Gu; M. Sahoo

    2005-04-01T23:59:59.000Z

    Grain refinement is a well established process for many cast and wrought alloys. The mechanical properties of various alloys could be enhanced by reducing the grain size. Refinement is also known to improve casting characteristics such as fluidity and hot tearing. Grain refinement of copper-base alloys is not widely used, especially in sand casting process. However, in permanent mold casting of copper alloys it is now common to use grain refinement to counteract the problem of severe hot tearing which also improves the pressure tightness of plumbing components. The mechanism of grain refinement in copper-base alloys is not well understood. The issues to be studied include the effect of minor alloy additions on the microstructure, their interaction with the grain refiner, effect of cooling rate, and loss of grain refinement (fading). In this investigation, efforts were made to explore and understand grain refinement of copper alloys, especially in permanent mold casting conditions.

  1. The Influence of Casting Conditions on the Microstructure of As-Cast U-10Mo Alloys: Characterization of the Casting Process Baseline

    SciTech Connect (OSTI)

    Nyberg, Eric A.; Joshi, Vineet V.; Lavender, Curt A.; Paxton, Dean M.; Burkes, Douglas

    2013-12-13T23:59:59.000Z

    Sections of eight plate castings of uranium alloyed with 10 wt% molybdenum (U-10Mo) were sent from Y-12 to the Pacific Northwest National Laboratory (PNNL) for microstructural characterization. This report summarizes the results from this study.

  2. Control of the specific growth rate of Bacillus subtilis for the production of biosurfactant lipopeptides in bioreactors with foam

    E-Print Network [OSTI]

    Boyer, Edmond

    lipopeptides in bioreactors with foam overflow S. CHENIKHERa , J. S. GUEZb , F. COUTTE b , M. PEKPEa , P

  3. Rigid polyurethane foams in refrigeration. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect (OSTI)

    Not Available

    1994-03-01T23:59:59.000Z

    The bibliography contains citations concerning the use of rigid polyurethane as thermal insulation in refrigerators. Production machinery, foam systems such as one-shot prepolymer systems, and properties of rigid polyurethane foams used in refrigerators are among the topics discussed. Curing methods, in-place foaming, and bun foaming are also included. (Contains a minimum of 70 citations and includes a subject term index and title list.)

  4. Polyurethane/polyisocyanurate foam thermal insulation. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect (OSTI)

    Not Available

    1994-06-01T23:59:59.000Z

    The bibliography contains citations concerning the use of polyisocyanurate/polyurethane foam for thermal insulation building materials. The topics discussed include flammability and smoke generation characteristics, building frame sheathing materials, fiber reinforcement, laminated insulation foam boards, substitution for controversial formaldehyde foams and aging characteristics. Performance evaluations of existing buildings with installed foam insulation are included. (Contains a minimum of 187 citations and includes a subject term index and title list.)

  5. Polystyrene foams for thermal insulation. (Latest citations from the Rubber and Plastics Research Asociation database). Published Search

    SciTech Connect (OSTI)

    Not Available

    1994-07-01T23:59:59.000Z

    The bibliography contains citations concerning the use of polystyrene foam as a thermal insulator. References discuss applications in railroad tracks, masonry walls, foundations for shallow buildings, and commercial roofing. Use as a vibration medium is referenced. Topics include designing with foam and self-extinguishing foams. (Contains a minimum of 77 citations and includes a subject term index and title list.)

  6. Use of Disinfectants and Cleaners to Reduce Bacteria on Poultry Transportation Coops with a Compressed Air Foam System†

    E-Print Network [OSTI]

    Hinojosa-Garza, Carolee A.

    2013-05-24T23:59:59.000Z

    and disinfect poultry transport coops. The objective of this study was to evaluate treatments consisting of a low-pressure water rinse (LPWR), a foaming additive alone, foaming cleaner or peroxyacetic acid with a foaming additive to reduce bacteria on broiler...

  7. Impact Strength of High Relative Density Solid State CO, Blown CPET Microcellular Foams Impact Strength of High Relative Density

    E-Print Network [OSTI]

    Kumar, Vipin

    is an increased glass transition temperature (T,), thus requiring higher foaming temperatures. Baldwin and SuhImpact Strength of High Relative Density Solid State CO, Blown CPET Microcellular Foams ImpactTerephthalate) Microcellular Foams Vipin KurnaW, Richard P Juntunena, and Chris Barlowb University of Washington, Seattle

  8. Yield drag in a two-dimensional foam flow around a circular obstacle: Effect of liquid fraction

    E-Print Network [OSTI]

    Cox, Simon

    Yield drag in a two-dimensional foam flow around a circular obstacle: Effect of liquid fraction of foams around a circular obstacle within a long channel. In experiments, we confine the foam between liquid and glass surfaces. In simulations, we use a deterministic software, the Surface Evolver

  9. Modeling of a Foamed Emulsion Bioreactor: I. Model Development and Experimental Validation

    E-Print Network [OSTI]

    ARTICLE Modeling of a Foamed Emulsion Bioreactor: I. Model Development and Experimental Validation, a new type of bioreactor for air pollution control referred to as the foamed emulsion bior- eactor (FEBR Introduction Biofilters and biotrickling filters are the most widely used bioreactors for treating low levels

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

    E-Print Network [OSTI]

    Cox, Simon

    Effect of Gas Diffusion on Mobility of Foam for Enhanced Oil Recovery Lars E. Nonnekes1 Foam can improve the sweep efficiency of gas injected into oil reservoirs for enhanced oil recovery University William Richard Rossen Email: W.R.Rossen@tudelft.nl Abstract Transport of gas across

  11. Polystyrene foam products equation of state as a function of porosity and fill gas

    SciTech Connect (OSTI)

    Mulford, Roberta N [Los Alamos National Laboratory; Swift, Damian C [LLNL

    2009-01-01T23:59:59.000Z

    An accurate EOS for polystyrene foam is necessary for analysis of numerous experiments in shock compression, inertial confinement fusion, and astrophysics. Plastic to gas ratios vary between various samples of foam, according to the density and cell-size of the foam. A matrix of compositions has been investigated, allowing prediction of foam response as a function of the plastic-to-air ratio. The EOS code CHEETAH allows participation of the air in the decomposition reaction of the foam. Differences between air-filled, Ar-blown, and CO{sub 2}-blown foams are investigated, to estimate the importance of allowing air to react with products of polystyrene decomposition. O{sub 2}-blown foams are included in some comparisons, to amplify any consequences of reaction with oxygen in air. He-blown foams are included in some comparisons, to provide an extremum of density. Product pressures are slightly higher for oxygen-containing fill gases than for non-oxygen-containing fill gases. Examination of product species indicates that CO{sub 2} decomposes at high temperatures.

  12. Multiple Percolation in a Carbon-Filled Polymer Composites via Foaming

    E-Print Network [OSTI]

    Thompson, Michael

    . However, there are few publi- cations reporting on the electrical conductivity of foam polymer composites6Multiple Percolation in a Carbon-Filled Polymer Composites via Foaming M. R. Thompson,1 G. H conductivity for a car- bon-filled cyclic olefin copolymer (COC) composite incorpo- rating both chopped carbon

  13. Foaming of E-Glass (Report for G Plus Project for PPG)

    SciTech Connect (OSTI)

    Kim, Dong-Sang; Hrma, Pavel R.; Pilon, Laurent; Dutton, Bryan C.

    2004-04-19T23:59:59.000Z

    The behavior of foams generated in the crucible melts was investigated to study the effect of furnace atmosphere on E-glass foaming, specifically focused on its water content to understand the effect of oxy-firing. A quartz-crucible furnace equipped with video recording was used to observe the behavior and to evaluate stability of foams generated from the PPG E-glass under various atmospheres. The present study preliminarily concluded that the higher foaming in oxy-fired furnace compared to air-fired is caused by the effect of water on early sulfate decomposition, promoting more efficient refining gas generation from sulfate (known as ''dilution effect''), not by the effect of humidity on foam lamella stability. A plausible explanation for the difference between soda-lime glass and E-glass in the end result of the dilution effect on glass refining and foaming is presented. A preliminary experiment on the effect of heating rate also suggests that thermal history of glass melting can be a major factor in the rate of E-glass foaming. Approaches to develop the methods to reduce foaming in oxy-fired furnace are recommended.

  14. Fracture enhanced in-situ foam remediation. Topical report, July 1995-December 1996

    SciTech Connect (OSTI)

    Chowdiah, P.; Misra, B.R.; Conrad, J.R.; Srivastava, V.J.

    1997-06-01T23:59:59.000Z

    The objective of this project was to determine the technical feasibility of soil fracturing as an enhancement to transportation of foam and foam-assisted site remediation. This project is part of an overall effort by the Gas Research Institute (GRI) to develop technologies for cost-effective, in-situ remediation of soils.

  15. Thermal degradation of new and aged urethane foam and epon 826 epoxy.

    SciTech Connect (OSTI)

    Kruizenga, Alan Michael; Mills, Bernice E.

    2013-08-01T23:59:59.000Z

    Thermal desorption spectroscopy was used to monitor the decomposition as a function of temperature for the foam and epoxy as a function of temperature in the range of 60C to 170C. Samples were studied with one day holds at each of the studied temperatures. Both new (FoamN and EpoxyN) and aged (FoamP and EpoxyP) samples were studied. During these ~10 day experiments, the foam samples lost 11 to 13% of their weight and the EpoxyN lost 10% of its weight. The amount of weight lost was difficult to quantify for EpoxyP because of its inert filler. The onset of the appearance of organic degradation products from FoamP began at 110C. Similar products did not appear until 120C for FoamN, suggesting some effect of the previous decades of storage for FoamP. In the case of the epoxies, the corresponding temperatures were 120C for EpoxyP and 110C for EpoxyN. Suggestions for why the aged epoxy seems more stable than newer sample include the possibility of incomplete curing or differences in composition. Recommendation to limit use temperature to 90-100C for both epoxy and foam.

  16. JOURNAL OF MATERIALS SCIENCE 34 (1999) 637 644 Cell nucleation in solid-state polymeric foams

    E-Print Network [OSTI]

    Kumar, Vipin

    JOURNAL OF MATERIALS SCIENCE 34 (1999) 637­ 644 Cell nucleation in solid-state polymeric foams-mail: holl@u.washington.edu The mechanism for nucleation phenomenon in solid-state microcellular foams. The nucleation phenomenon is thermally activated at the effective glass transition temperature of the gas

  17. Method of casting silicon into thin sheets

    DOE Patents [OSTI]

    Sanjurjo, Angel (San Jose, CA); Rowcliffe, David J. (Los Altos, CA); Bartlett, Robert W. (Tucson, AZ)

    1982-10-26T23:59:59.000Z

    Silicon (Si) is cast into thin shapes within a flat-bottomed graphite crucible by providing a melt of molten Si along with a relatively small amount of a molten salt, preferably NaF. The Si in the resulting melt forms a spherical pool which sinks into and is wetted by the molten salt. Under these conditions the Si will not react with any graphite to form SiC. The melt in the crucible is pressed to the desired thinness with a graphite tool at which point the tool is held until the mass in the crucible has been cooled to temperatures below the Si melting point, at which point the Si shape can be removed.

  18. Eect of imperfections on the yielding of two-dimensional foams

    E-Print Network [OSTI]

    Fleck, Norman A.

    ģcation. For instance, a batch casting method is used by Shinko Wire to manufacture a closed cell aluminium alloy foa

  19. Plasticity of sandwich beam withPlasticity of sandwich beam withPlasticity of sandwich beam withPlasticity of sandwich beam with metallic foam coremetallic foam coremetallic foam coremetallic foam core

    E-Print Network [OSTI]

    Luo, Xiaoyu

    Plasticity of sandwich beam withPlasticity of sandwich beam withPlasticity of sandwich beam withPlasticity-- · Plasticity of lightweight sandwich structures, 2006 --Plasticity of lightweight sandwich structures, 2006 --Plasticity of lightweight sandwich structures, 2006 --Plasticity of lightweight sandwich structures, 2006

  20. Spray Foam Exterior Insulation with Stand-Off Furring

    SciTech Connect (OSTI)

    Herk, A.; Baker, R.; Prahl, D.

    2014-03-01T23:59:59.000Z

    IBACOS, in collaboration with GreenHomes America, was contracted by the New York State Energy Research and Development Authority to research exterior wall insulation solutions. This research investigated cost-effective deep energy retrofit (DER) solutions for improving the building shell exterior while achieving a cost-reduction goal, including reduced labor costs to reach a 50/50 split between material and labor. The strategies included exterior wall insulation plus energy upgrades as needed in the attic, mechanical and ventilation systems, and basement band joist, walls, and floors. The work can be integrated with other home improvements such as siding or window replacement. This strategy minimizes physical connections to existing wall studs, encapsulates existing siding materials (including lead paint) with spray foam, and creates a vented rain screen assembly to promote drying. GreenHomes America applied construction details created by IBACOS to a test home. 2x4 framing members were attached to the wall at band joists and top plates using 'L' clips, with spray foam insulating the wall after framing was installed. Windows were installed simultaneously with the framing, including extension jambs. The use of clips in specific areas provided the best strength potential, and 'picture framing' the spray foam held the 2x4s in place. Short-term testing was performed at this house, with monitoring equipment installed for long-term testing. Testing measurements will be provided in a later report, as well as utility impact (before and after), costs (labor and materials), construction time, standard specifications, and analysis for the exterior wall insulation strategy.

  1. Fluid flow and heat transfer modeling for castings

    SciTech Connect (OSTI)

    Domanus, H.M.; Liu, Y.Y.; Sha, W.T.

    1986-01-01T23:59:59.000Z

    Casting is fundamental to manufacturing of many types of equipment and products. Although casting is a very old technology that has been in existence for hundreds of years, it remains a highly empirical technology, and production of new castings requires an expensive and time-consuming trial-and-error approach. In recent years, mathematical modeling of casting has received increasing attention; however, a majority of the modeling work has been in the area of heat transfer and solidification. Very little work has been done in modeling fluid flow of the liquid melt. This paper presents a model of fluid flow coupled with heat transfer of a liquid melt for casting processes. The model to be described in this paper is an extension of the COMMIX code and is capable of handling castings with any shape, size, and material. A feature of this model is the ability to track the liquid/gas interface and liquid/solid interface. The flow of liquid melt through the sprue and runners and into the mold cavity is calculated as well as three-dimensional temperature and velocity distributions of the liquid melt throughout the casting process. 14 refs., 13 figs.

  2. Corrosion-resistant Foamed Cements for Carbon Steels

    SciTech Connect (OSTI)

    Sugama T.; Gill, S.; Pyatina, T., Muraca, A.; Keese, R.; Khan, A.; Bour, D.

    2012-12-01T23:59:59.000Z

    The cementitious material consisting of Secar #80, Class F fly ash, and sodium silicate designed as an alternative thermal-shock resistant cement for the Enhanced Geothermal System (EGS) wells was treated with cocamidopropyl dimethylamine oxide-based compound as foaming agent (FA) to prepare numerous air bubble-dispersed low density cement slurries of and #61603;1.3 g/cm3. Then, the foamed slurry was modified with acrylic emulsion (AE) as corrosion inhibitor. We detailed the positive effects of the acrylic polymer (AP) in this emulsion on the five different properties of the foamed cement: 1) The hydrothermal stability of the AP in 200 and #61616;C-autoclaved cements; 2) the hydrolysis-hydration reactions of the slurry at 85 and #61616;C; 3) the composition of crystalline phases assembled and the microstructure developed in autoclaved cements; 4) the mechanical behaviors of the autoclaved cements; and, 5) the corrosion mitigation of carbon steel (CS) by the polymer. For the first property, the hydrothermal-catalyzed acid-base interactions between the AP and cement resulted in Ca-or Na-complexed carboxylate derivatives, which led to the improvement of thermal stability of the AP. This interaction also stimulated the cement hydration reactions, enhancing the total heat evolved during cementís curing. Addition of AP did not alter any of the crystalline phase compositions responsible for the strength of the cement. Furthermore, the AP-modified cement developed the porous microstructure with numerous defect-free cavities of disconnected voids. These effects together contributed to the improvement of compressive-strength and Ėtoughness of the cured cement. AP modification of the cement also offered an improved protection of CS against brine-caused corrosion. There were three major factors governing the corrosion protection: 1) Reducing the extents of infiltration and transportation of corrosive electrolytes through the cement layer deposited on the underlying CS surfaces; 2) inhibiting the cathodic reactions at the corrosion site of CS; 3) extending the coverage of cement over CS surfaces; and, 4) improving the adherence of the cement to CS surfaces. Thus, the CSís corrosion rate of 176 milli inch/per year (mpy) for 1 wt% FA-foamed cement without AP was considerably reduced to 69 mpy by adding only 2 wt% AP. Addition of AP at 10 wt% further reduced this rate to less than 10 mpy.

  3. Hanford's Simulated Low Activity Waste Cast Stone Processing

    SciTech Connect (OSTI)

    Kim, Young

    2013-08-20T23:59:59.000Z

    Cast Stone is undergoing evaluation as the supplemental treatment technology for Hanfordís (Washington) high activity waste (HAW) and low activity waste (LAW). This report will only cover the LAW Cast Stone. The programs used for this simulated Cast Stone were gradient density change, compressive strength, and salt waste form phase identification. Gradient density changes show a favorable outcome by showing uniformity even though it was hypothesized differently. Compressive strength exceeded the minimum strength required by Hanford and greater compressive strength increase seen between the uses of different salt solution The salt waste form phase is still an ongoing process as this time and could not be concluded.

  4. Materials Science and Engineering A, 2006. 417(1-2): p. 249-258 249 Investigation of Flexural Strength Properties of Rubber and Nanoclay Reinforced Hybrid Syntactic Foams

    E-Print Network [OSTI]

    Gupta, Nikhil

    Strength Properties of Rubber and Nanoclay Reinforced Hybrid Syntactic Foams Rahul Maharsia* , Nikhil Gupta are developed by using rubber and nanoclay particles to modify the matrix microstructure in syntactic foams to fabricate the foam samples. In the rubber hybrid foams, 40 and 75 m size rubber particles are used by 2

  5. Rigid polyurethane foams in refrigeration. January 1973-July 1989 (Citations from the Rubber and Plastics Research Association data base). Report for January 1973-July 1989

    SciTech Connect (OSTI)

    Not Available

    1989-08-01T23:59:59.000Z

    This bibliography contains citations concerning the use of rigid polyurethane as thermal insulation in refrigerators. Production machinery, foam systems such as one-shot prepolymer systems, and properties of rigid polyurethane foams used in refrigerators are among the topics discussed. Curing methods, in-place foaming, and bun foaming are also included. (Contains 74 citations fully indexed and including a title list.)

  6. Applied Composite Materials, 2005. 12(3-4): p. 247-261 247 Enhancement of Energy Absorption in Syntactic Foams by Nanoclay Incorporation for Sandwich

    E-Print Network [OSTI]

    Gupta, Nikhil

    70803 ABSTRACT Syntactic foams are closed pore foams fabricated by the mechanical mixing of hollow glass in Syntactic Foams by Nanoclay Incorporation for Sandwich Core Applications Nikhil Gupta1 and Rahul Maharsia2 foams due to the incorporation of nano-sized clay (nanoclay) particles. A surface modified clay, Nanomer

  7. Metal aminoboranes

    DOE Patents [OSTI]

    Burrell, Anthony K.; Davis, Benjamin J.; Thorn, David L.; Gordon, John C.; Baker, R. Thomas; Semelsberger, Troy Allen; Tumas, William; Diyabalanage, Himashinie Vichalya; Shrestha, Roshan P.

    2010-05-11T23:59:59.000Z

    Metal aminoboranes of the formula M(NH2BH3)n have been synthesized. Metal aminoboranes are hydrogen storage materials. Metal aminoboranes are also precursors for synthesizing other metal aminoboranes. Metal aminoboranes can be dehydrogenated to form hydrogen and a reaction product. The reaction product can react with hydrogen to form a hydrogen storage material. Metal aminoboranes can be included in a kit.

  8. Method and apparatus for producing a carbon based foam article having a desired thermal-conductivity gradient

    DOE Patents [OSTI]

    Klett, James W. (Knoxville, TN) [Knoxville, TN; Cameron, Christopher Stan (Sanford, NC) [Sanford, NC

    2010-03-02T23:59:59.000Z

    A carbon based foam article is made by heating the surface of a carbon foam block to a temperature above its graphitizing temperature, which is the temperature sufficient to graphitize the carbon foam. In one embodiment, the surface is heated with infrared pulses until heat is transferred from the surface into the core of the foam article such that the graphitizing temperature penetrates into the core to a desired depth below the surface. The graphitizing temperature is maintained for a time sufficient to substantially entirely graphitize the portion of the foam article from the surface to the desired depth below the surface. Thus, the foam article is an integral monolithic material that has a desired conductivity gradient with a relatively high thermal conductivity in the portion of the core that was graphitized and a relatively low thermal conductivity in the remaining portion of the foam article.

  9. aluminum die casting: Topics by E-print Network

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

    for Testing and Materials. Philadelphia 2005-01-01 7 Prediction of Thermal Fatigue in Tooling for Die-casting Copper via Finite Element Analysis CiteSeer Summary: Abstract. Recent...

  10. aluminum casting technology: Topics by E-print Network

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

    Ozgur. 2006-01-01 28 DESIGN AND MANUFACTURE OF CASTING PATTERN PLATES BY RAPID TOOLING. CiteSeer Summary: The primary target of this project consists of combining the...

  11. alloy die casting: Topics by E-print Network

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

    John G. Cowie; Edwin F. Brush; Stephen P. Midson 5 Prediction of Thermal Fatigue in Tooling for Die-casting Copper via Finite Element Analysis CiteSeer Summary: Abstract. Recent...

  12. additional die casting: Topics by E-print Network

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

    into contact... Ambs, L.; Kosanovic, D.; Edberg, C. 5 Prediction of Thermal Fatigue in Tooling for Die-casting Copper via Finite Element Analysis CiteSeer Summary: Abstract. Recent...

  13. aluminium die casting: Topics by E-print Network

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

    into contact... Ambs, L.; Kosanovic, D.; Edberg, C. 8 Prediction of Thermal Fatigue in Tooling for Die-casting Copper via Finite Element Analysis CiteSeer Summary: Abstract. Recent...

  14. alloy die castings: Topics by E-print Network

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

    John G. Cowie; Edwin F. Brush; Stephen P. Midson 5 Prediction of Thermal Fatigue in Tooling for Die-casting Copper via Finite Element Analysis CiteSeer Summary: Abstract. Recent...

  15. An Energy Savings Model for the Heat Treatment of Castings

    SciTech Connect (OSTI)

    Y. Rong; R. Sisson; J. Morral; H. Brody

    2006-12-31T23:59:59.000Z

    An integrated system of software, databases, and design rules have been developed, verified, and to be marketed to enable quantitative prediction and optimization of the heat treatment of aluminum castings to increase quality, increase productivity, reduce heat treatment cycle times and reduce energy consumption. The software predicts the thermal cycle in critical locations of individual components in a furnace, the evolution of microstructure, and the attainment of properties in heat treatable aluminum alloy castings. The model takes into account the prior casting process and the specific composition of the component. The heat treatment simulation modules can be used in conjunction with software packages for simulation of the casting process. The system is built upon a quantitative understanding of the kinetics of microstructure evolution in complex multicomponent alloys, on a quantitative understanding of the interdependence of microstructure and properties, on validated kinetic and thermodynamic databases, and validated quantitative models.

  16. Search for low Energy solar Axions with CAST

    E-Print Network [OSTI]

    Arik, E; Autiero, D; Barth, K; Belov, A; BeltrŠn, B; Borghi, S; Boydag, F S; Bršuninger, H; Cantatore, G; Carmona, J M; CebriŠn, S; Cetin, S A; Collar, J I; Dafni, T; Davenport, M; Di Lella, L; Dogan, O B; Eleftheriadis, C; Elias, N; Fanourakis, G K; Ferrer-Ribas, E; Fischer, H; Franz, J; GalŠn, J; Gazis, E; Geralis, T; Giomataris, Ioanis; Gninenko, S; Gůmez, H; Hasinoff, M; Heinsius, F H; Hikmet, I; Hoffmann, D H H; Irastorza, I G; Jacoby, J; Jakovicic, K; Kang, D; Karageorgopoulou, T; Karuza, M; KŲnigsmann, K C; Kotthaus, R; Krcmar, M; Kousouris, K; Kuster, M; Lakic, B; Lasseur, C; Liolios, A; Ljubicic, A; Lozza, V; Lutz, G; Luzůn, G; Miller, D; Morales, A; Morales, J; Niinikoski, T; Nordt, A; Ortiz, A; Papaevangelou, T; Pivovaroff, M; Placci, A; Raiteri, G; Raffelt, G; Riege, H; RodrŪguez, A; Ruz, J; Savvidis, I; Semertzidis, Y; Serpico, Pasquale Dario; Solanki, S K; Soufli, R; Stewart, L; Tsagri, M; Van Bibber, K; Villar, J; Vogel, J; Walckiers, L; Zioutas, K

    2008-01-01T23:59:59.000Z

    We have started the development of a detector system, sensitive to single photons in the eV energy range, to be suitably coupled to one of the CAST magnet ports. This system should open to CAST a window on possible detection of low energy Axion Like Particles emitted by the sun. Preliminary tests have involved a cooled photomultiplier tube coupled to the CAST magnet via a Galileian telescope and a switched 40 m long optical fiber. This system has reached the limit background level of the detector alone in ideal conditions, and two solar tracking runs have been performed with it at CAST. Such a measurement has never been done before with an axion helioscope. We will present results from these runs and briefly discuss future detector developments.

  17. Search for low Energy solar Axions with CAST

    E-Print Network [OSTI]

    Giovanni Cantatore; for the CAST Collaboration; :; E. Arik; S. Aune; D. Autiero; K. Barth; A. Belov; B. BeltrŠn; S. Borghi; F. S. Boydag; H. Bršuninger; G. Cantatore; J. M. Carmona; S. CebriŠn; 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. GalŠn; E. Gazis; T. Geralis; I. Giomataris; S. Gninenko; H. Gůmez; 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. KŲnigsmann; R. Kotthaus; M. Kr?mar; K. Kousouris; M. Kuster; B. Laki?; C. Lasseur; A. Liolios; A. Ljubi?i?; V. Lozza; G. Lutz; G. Luzůn; D. Miller; A. Morales; {deceased}; J. Morales; T. Niinikoski; A. Nordt; A. Ortiz; T. Papaevangelou; M. Pivovaroff; A. Placci; G. Raiteri; G. Raffelt; H. Riege; A. RodrŪguez; J. Ruz; I. Savvidis; Y. Semertzidis; P. Serpico; S. K. Solanki; R. Soufli; L. Stewart; M. Tsagri; K. van Bibber; J. Villar; J. Vogel; L. Walckiers; K. Zioutas

    2008-09-29T23:59:59.000Z

    We have started the development of a detector system, sensitive to single photons in the eV energy range, to be suitably coupled to one of the CAST magnet ports. This system should open to CAST a window on possible detection of low energy Axion Like Particles emitted by the sun. Preliminary tests have involved a cooled photomultiplier tube coupled to the CAST magnet via a Galileian telescope and a switched 40 m long optical fiber. This system has reached the limit background level of the detector alone in ideal conditions, and two solar tracking runs have been performed with it at CAST. Such a measurement has never been done before with an axion helioscope. We will present results from these runs and briefly discuss future detector developments.

  18. In Search Of Axions: The CAST Experiment George K. Fanourakis

    E-Print Network [OSTI]

    Hudson, Hugh

    , Greece Abstract. The CERN Axion Solar Telescope (CAST) experiment uses a decommissioned LHC test magnet-Planck-Institut fur Extraterrestrische Physik, Garching, Germany, 6 Instituto de Fisica Nuclear y Altas Energias

  19. Microstructure of thin-wall ductile iron castings

    SciTech Connect (OSTI)

    Dogan, Omer N.; Schrems, Karol K.; Hawk, Jeffrey A.

    2003-01-01T23:59:59.000Z

    Step plate castings with section thicknesses of 1.5 mm to 6 mm and individual (single) castings with section thicknesses of 2 mm to 6 mm were produced using a ductile iron chemistry. Microstructures of these thin wall ductal iron castings were characterized quantitatively using an image analyzer. Matrix structure (amount of pearlite, ferrite, and massive carbides) and graphite structure (volume fraction, nodule size, nodule content, and nodularity) were investigated as a function of section thickness. Pearlite content, nodule count, and nodularity increased with decreasing section thickness, whereas the nodule size decreased. Nodule content exceeded 2000 nodules per mm{sup 2} at the thinnest sections. Statistical analysis was performed to investigate the effect of casting parameters on the microstructure.

  20. Marry for What? Caste and Mate Selection in Modern India

    E-Print Network [OSTI]

    Banerjee, Abhijit

    This paper analyzes how preferences for a noneconomic characteristic (e.g., caste) can affect equilibrium patterns of matching, and empirically evaluates this in the context of middle-class Indian arranged marriages. We ...

  1. Molten metal feed system controlled with a traveling magnetic field

    DOE Patents [OSTI]

    Praeg, Walter F. (Palos Park, IL)

    1991-01-01T23:59:59.000Z

    A continuous metal casting system in which the feed of molten metal is controlled by means of a linear induction motor capable of producing a magnetic traveling wave in a duct that connects a reservoir of molten metal to a caster. The linear induction motor produces a traveling magnetic wave in the duct in opposition to the pressure exerted by the head of molten metal in the reservoir so that p.sub.c =p.sub.g -p.sub.m where p.sub.c is the desired pressure in the caster, p.sub.g is the gravitational pressure in the duct exerted by the force of the head of molten metal in the reservoir, and p.sub.m is the electromagnetic pressure exerted by the force of the magnetic field traveling wave produced by the linear induction motor. The invention also includes feedback loops to the linear induction motor to control the casting pressure in response to measured characteristics of the metal being cast.

  2. Methods for manufacturing monocrystalline or near-monocrystalline cast materials

    DOE Patents [OSTI]

    Stoddard, Nathan G

    2014-04-29T23:59:59.000Z

    Methods are provided for casting one or more of a semiconductor, an oxide, and an intermetallic material. With such methods, a cast body of a monocrystalline form of the one or more of a semiconductor, an oxide, and an intermetallic material 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.

  3. Methods for manufacturing geometric multi-crystalline cast materials

    DOE Patents [OSTI]

    Stoddard, Nathan G

    2013-11-26T23:59:59.000Z

    Methods are provided for casting one or more of a semi-conductor, an oxide, and an intermetallic material. With such methods, a cast body of a geometrically ordered multi-crystalline form of the one or more of a semiconductor, an oxide, and an intermetallic material may be formed that is free or substantially free of radially-distributed impurities and defects and having at least two dimensions that are each at least about 10 cm.

  4. Procedure for flaw detection in cast stainless steel

    DOE Patents [OSTI]

    Kupperman, David S. (Oak Park, IL)

    1988-01-01T23:59:59.000Z

    A method of ultrasonic flaw detection in cast stainless steel components incorporating the steps of determining the nature of the microstructure of the cast stainless steel at the site of the flaw detection measurements by ultrasonic elements independent of the component thickness at the site; choosing from a plurality of flaw detection techniques, one such technique appropriate to the nature of the microstructure as determined and detecting flaws by use of the chosen technique.

  5. Predicting Pattern Tooling and Casting Dimensions for Investment Casting, Phase II

    SciTech Connect (OSTI)

    Nick Cannell (EMTEC); Adrian S. Sabau (ORNL)

    2005-09-30T23:59:59.000Z

    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 first part of the project involved preparation of reports on the state of the art at that time for all the areas under consideration (die-wax, wax-shell, and shell-alloy). The primary R&D focus during Phase I was on the wax material since the least was known about it. The main R&D accomplishments during this phase were determination of procedures for obtaining the thermal conductivity and viscoelastic properties of an unfilled wax and validating those procedures. Phase II focused on die-wax and shell-alloy systems. A wax material model was developed based on results obtained during the previous R&D phase, and a die-wax model was successfully incorporated into and used in commercial computer programs. Current computer simulation programs have complementary features. A viscoelastic module was available in ABAQUS but unavailable in ProCAST, while the mold-filling module was available in ProCAST but unavailable in ABAQUS. Thus, the numerical simulation results were only in good qualitative agreement with experimental results, the predicted shrinkage factors being approximately 2.5 times larger than those measured. Significant progress was made, and results showed that the testing and modeling of wax material had great potential for industrial applications. Additional R&D focus was placed on one shell-alloy system. The fused-silica shell mold and A356 aluminum alloy were considered. The experimental part of the program was conducted at ORNL and commercial foundries, where wax patterns were injected, molds were invested, and alloys were poured. It was very important to obtain accurate temperature data from actual castings, and significant effort was made to obtain temperature profiles in the shell mold. A model for thermal radiation within the shell mold was developed, and the thermal model was successfully validated using ProCAST. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The prefiring of the empty shell mold was considered in the model, and the shell mold was limited to a pure elastic material. The alloy dimensions were obtained from numerical simulations only with coupled shell-alloy systems. The alloy dimensions were in excellent quantitative agreement with experimental data, validating the deformation module. For actual parts, however, the creep properties of the shell molds must also be obtained, modeled, and validated.

  6. Letter Report: LAW Simulant Development for Cast Stone Screening Test

    SciTech Connect (OSTI)

    Russell, Renee L.; Westsik, Joseph H.; Swanberg, David J.; Eibling, Russell E.; Cozzi, Alex; Lindberg, Michael J.; Josephson, Gary B.; Rinehart, Donald E.

    2013-03-27T23:59:59.000Z

    More than 56 million gallons of radioactive and hazardous waste are stored in 177 underground storage tanks at the U.S. Department of Energyís (DOEís) Hanford Site in southeastern Washington State. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is being constructed to treat the wastes and immobilize them in a glass waste form. The WTP includes a pretreatment facility to separate the wastes into a small volume of high-level waste (HLW) containing most of the radioactivity and a larger volume of low-activity waste (LAW) containing most of the nonradioactive chemicals. The HLW will be converted to glass in the HLW vitrification facility for ultimate disposal at an offsite federal repository. At least a portion (~35%) of the LAW will be converted to glass in the LAW vitrification facility and will be disposed of onsite at the Integrated Disposal Facility (IDF). The pretreatment and HLW vitrification facilities will have the capacity to treat and immobilize the wastes destined for each facility. However, a second facility will be needed for the expected volume of additional LAW requiring immobilization. A cementitious waste form known as Cast Stone is being considered to provide the required additional LAW immobilization capacity. The Cast Stone waste form must be acceptable for disposal in the IDF. The Cast Stone waste form and immobilization process must be tested to demonstrate that the final Cast Stone waste form can comply with waste acceptance criteria for the IDF disposal facility and that the immobilization processes can be controlled to consistently provide an acceptable waste form product. Further, the waste form must be tested to provide the technical basis for understanding the long term performance of the waste form in the IDF disposal environment. These waste form performance data are needed to support risk assessment and performance assessment (PA) analyses of the long-term environmental impact of the waste disposal in the IDF. A testing program was developed in fiscal year (FY) 2012 describing in some detail the work needed to develop and qualify Cast Stone as a waste form for the solidification of Hanford LAW (Westsik et al. 2012). Included within Westsik et al. (2012) is a section on the near-term needs to address Tri-Party Agreement Milestone M-062-40ZZ. The objectives of the testing program to be conducted in FY 2013 and FY 2014 are to: ē Determine an acceptable formulation for the LAW Cast Stone waste form. ē Evaluate sources of dry materials for preparing the LAW Cast Stone. ē Demonstrate the robustness of the Cast Stone waste form for a range of LAW compositions. ē Demonstrate the robustness of the formulation for variability in the Cast Stone process. ē Provide Cast Stone contaminant release data for PA and risk assessment evaluations. The first step in determining an acceptable formulation for the LAW Cast Stone waste form is to conduct screening tests to examine expected ranges in pretreated LAW composition, waste stream concentrations, dry-materials sources, and mix ratios of waste feed to dry blend. A statistically designed test matrix will be used to evaluate the effects of these key parameters on the properties of the Cast Stone as it is initially prepared and after curing. The second phase of testing will focus on selection of a baseline Cast Stone formulation for LAW and demonstrating that Cast Stone can meet expected waste form requirements for disposal in the IDF. It is expected that this testing will use the results of the screening tests to define a smaller suite of tests to refine the composition of the baseline Cast Stone formulation (e.g. waste concentration, water to dry mix ratio, waste loading).

  7. Foam composition for treating asbestos-containing materials and method of using same

    DOE Patents [OSTI]

    Block, J.; Krupkin, N.V.; Kuespert, D.R.; Nishioka, G.M.; Lau, J.W.K.; Palmer, N.I.

    1998-04-28T23:59:59.000Z

    A composition for transforming a chrysotile asbestos-containing material into a non-asbestos material is disclosed. The composition comprises water, at least about 30% by weight of an acid component, at least about 0.1% by weight of a source of fluoride ions, and a stable foam forming amount of a foaming agent system having both cationic and non-ionic functionality. A method of transforming the asbestos-containing material into a non-asbestos material using the present composition in the form of a foam also disclosed.

  8. Heat transfer in sound propagation and attenuation through gas-liquid polyhedral foams

    E-Print Network [OSTI]

    Yuri M. Shtemler; Isaac R. Shreiber

    2007-05-20T23:59:59.000Z

    A cell method is developed, which takes into account the bubble geometry of polyhedral foams, and provides for the generalized Rayleigh-Plesset equation that contains the non-local in time term corresponding to heat relaxation. The Rayleigh-Plesset equation together with the equations of mass and momentum balances for an effective single-phase inviscid fluid yield a model for foam acoustics. The present calculations reconcile observed sound velocity and attenuation with those predicted using the assumption that thermal dissipation is the dominant damping mechanism in a range of foam expansions and sound excitation frequencies.

  9. An evaluation of direct pressure sensors for monitoring the aluminum die casting process

    SciTech Connect (OSTI)

    Zhang, X.

    1997-12-31T23:59:59.000Z

    This study was conducted as part of the US Department of Energy (DOE) sponsored project Die Cavity Instrumentation. One objective of that project was to evaluate thermal, pressure, and gas flow process monitoring sensors in or near the die cavity as a means of securing improved process monitoring and control and better resultant part quality. The objectives of this thesis are to (1) evaluate a direct cavity pressure sensor in a controlled production campaign at the GM Casting Advanced Development Center (CADC) at Bedford, Indiana; and (2) develop correlations between sensor responses and product quality in terms of the casting weight, volume, and density. A direct quartz-based pressure sensor developed and marked by Kistler Instrument Corp. was acquired for evaluating as an in-cavity liquid metal pressure sensor. This pressure sensor is designed for use up to 700 C and 2,000 bars (29,000 psi). It has a pressure overload capacity up to 2,500 bars (36,250 psi).

  10. Alloy with metallic glass and quasi-crystalline properties

    DOE Patents [OSTI]

    Xing, Li-Qian; Hufnagel, Todd C.; Ramesh, Kaliat T.

    2004-02-17T23:59:59.000Z

    An alloy is described that is capable of forming a metallic glass at moderate cooling rates and exhibits large plastic flow at ambient temperature. Preferably, the alloy has a composition of (Zr, Hf).sub.a Ta.sub.b Ti.sub.c Cu.sub.d Ni.sub.e Al.sub.f, where the composition ranges (in atomic percent) are 45.ltoreq.a.ltoreq.70, 3.ltoreq.b.ltoreq.7.5, 0.ltoreq.c.ltoreq.4, 3.ltoreq.b+c.ltoreq.10, 10.ltoreq.d.ltoreq.30, 0.ltoreq.e.ltoreq.20, 10.ltoreq.d+e.ltoreq.35, and 5.ltoreq.f.ltoreq.15. The alloy may be cast into a bulk solid with disordered atomic-scale structure, i.e., a metallic glass, by a variety of techniques including copper mold die casting and planar flow casting. The as-cast amorphous solid has good ductility while retaining all of the characteristic features of known metallic glasses, including a distinct glass transition, a supercooled liquid region, and an absence of long-range atomic order. The alloy may be used to form a composite structure including quasi-crystals embedded in an amorphous matrix. Such a composite quasi-crystalline structure has much higher mechanical strength than a crystalline structure.

  11. Secondary Waste Cast Stone Waste Form Qualification Testing Plan

    SciTech Connect (OSTI)

    Westsik, Joseph H.; Serne, R. Jeffrey

    2012-09-26T23:59:59.000Z

    The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is being constructed to treat the 56 million gallons of radioactive waste stored in 177 underground tanks at the Hanford Site. The WTP includes a pretreatment facility to separate the wastes into high-level waste (HLW) and low-activity waste (LAW) fractions for vitrification and disposal. The LAW will be converted to glass for final disposal at the Integrated Disposal Facility (IDF). Cast Stone Ė a cementitious waste form, has been selected for solidification of this secondary waste stream after treatment in the ETF. The secondary-waste Cast Stone waste form must be acceptable for disposal in the IDF. This secondary waste Cast Stone waste form qualification testing plan outlines the testing of the waste form and immobilization process to demonstrate that the Cast Stone waste form can comply with the disposal requirements. Specifications for the secondary-waste Cast Stone waste form have not been established. For this testing plan, Cast Stone specifications are derived from specifications for the immobilized LAW glass in the WTP contract, the waste acceptance criteria for the IDF, and the waste acceptance criteria in the IDF Permit issued by the State of Washington. This testing plan outlines the testing needed to demonstrate that the waste form can comply with these waste form specifications and acceptance criteria. The testing program must also demonstrate that the immobilization process can be controlled to consistently provide an acceptable waste form product. This testing plan also outlines the testing needed to provide the technical basis for understanding the long-term performance of the waste form in the disposal environment. These waste form performance data are needed to support performance assessment analyses of the long-term environmental impact of the secondary-waste Cast Stone waste form in the IDF

  12. Yield improvement and defect reduction in steel casting

    SciTech Connect (OSTI)

    Kent Carlson

    2004-03-16T23:59:59.000Z

    This research project investigated yield improvement and defect reduction techniques in steel casting. Research and technology development was performed in the following three specific areas: (1) Feeding rules for high alloy steel castings; (2) Unconventional yield improvement and defect reduction techniques--(a) Riser pressurization; and (b) Filling with a tilting mold; and (3) Modeling of reoxidation inclusions during filling of steel castings. During the preparation of the proposal for this project, these areas were identified by the High Alloy Committee and Carbon and Low Alloy Committee of the Steel Founders' Society of America (SFSA) as having the highest research priority to the steel foundry industry. The research in each of the areas involved a combination of foundry experiments, modeling and simulation. Numerous SFSA member steel foundries participated in the project through casting trials and meetings. The technology resulting from this project will result in decreased scrap and rework, casting yield improvement, and higher quality steel castings produced with less iteration. This will result in considerable business benefits to steel foundries, primarily due to reduced energy and labor costs, increased capacity and productivity, reduced lead-time, and wider use and application of steel castings. As estimated using energy data provided by the DOE, the technology produced as a result of this project will result in an energy savings of 2.6 x 10{sup 12} BTU/year. This excludes the savings that were anticipated from the mold tilting research. In addition to the energy savings, and corresponding financial savings this implies, there are substantial environmental benefits as well. The results from each of the research areas listed above are summarized.

  13. Method for forming a uniformly dense polymer foam body

    DOE Patents [OSTI]

    Whinnery, Jr., Leroy (Danville, CA)

    2002-01-01T23:59:59.000Z

    A method for providing a uniformly dense polymer foam body having a density between about 0.013 .sup.g /.sub.cm.sup..sub.3 to about 0.5 .sup.g /.sub.cm.sup..sub.3 is disclosed. The method utilizes a thermally expandable polymer microballoon material wherein some of the microballoons are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about 130.degree. C., and then cooling the mold to a temperature below 80.degree. C. the molded part achieves a bulk density which varies by less then about .+-.6% everywhere throughout the part volume.

  14. Developing & tailoring multi-functional carbon foams for multi-field response

    E-Print Network [OSTI]

    Sarzynski, Melanie Diane

    2009-05-15T23:59:59.000Z

    anisotropy and coatings to provide comprehensive information to guide processing researchers in their pursuit of tailorable performance. Several illustrations are undertaken at multiple scales to explore the response of multi-functional carbon foams under...

  15. Application of Genetic Algorithms and Thermogravimetry to Determine the Kinetics of Polyurethane Foam in Smoldering Combustion†

    E-Print Network [OSTI]

    Rein, Guillermo; Lautenberger, Chris; Fernandez-Pello, Carlos; Torero, Jose L; Urban, David

    In this work, the kinetic parameters governing the thermal and oxidative degradation of flexible polyurethane foam are determined using thermogravimetric data and a genetic algorithm. These kinetic parameters are needed ...

  16. Developing & tailoring multi-functional carbon foams for multi-field response†

    E-Print Network [OSTI]

    Sarzynski, Melanie Diane

    2009-05-15T23:59:59.000Z

    anisotropy and coatings to provide comprehensive information to guide processing researchers in their pursuit of tailorable performance. Several illustrations are undertaken at multiple scales to explore the response of multi-functional carbon foams under...

  17. Stimulation results in the low-permeability Wasatch formation - An evolution to foam fracturing

    SciTech Connect (OSTI)

    Harris, P.C.; Bailey, D.E.; Evertz, G.L.

    1984-05-01T23:59:59.000Z

    The Wasatch Formation of the Uinta Basin in eastern Utah is typical of many formations in the Rocky Mountains, having low permeability and high sensitivity to water. Stimulation treatments with several types of fracturing fluids, including oilwater emulsion fluids, complex gel fluids and foam fluids, have been generally successful. Production decline curves from twenty four wells in the field were used for comparison of the different stimulation methods. Although foam fracturing has been used for the shortest period of time, comparison of the production histories show the relatively higher efficiency of the foam fracturing treatments compared to other stimulation methods in the Wasatch formation. Foam fluids gave higher production rates and higher flowing pressures than offset wells fractured with complex gel fluids. A stimulation model for oil and gas production was used to match the production history from this reservoir. The model allowed a projection of gas production based on early production from the wells and knowledge of the reservoir.

  18. Effect of microstructure of closed cell foam on strength and effective stiffness

    E-Print Network [OSTI]

    Sue, Ji Woong

    2007-04-25T23:59:59.000Z

    structure of the foam. A low- boiling, inert liquid fluorocarbon is mixed in with the polyol. When the polymerization reaction takes place, the exotherm is sufficient to cause the fluorocarbon to volatilize and act as blowing agent. It should also...

  19. Microsoft Word - NETL-TRS-2-2013_Foamed Cement_20140124.docx

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

    Foamed Cement 1 ABSTRACT NETL researchers have produced the first high-resolution X-ray computed tomography (CT) three-dimensional (3-D) images of atmospheric-generated...

  20. Laboratory and field evaluation of polyurethane foam for lost circulation control

    SciTech Connect (OSTI)

    Glowka, D.A.; Loeppke, G.E.; Rand, P.B.; Wright, E.K. (Sandia National Labs., Albuquerque, NM (USA))

    1989-01-01T23:59:59.000Z

    A two-part polyurethane foam has been tested in the laboratory and in the field to assess its utility in controlling lost circulation encountered when drilling geothermal wells. A field test was conducted in The Geysers in January, 1988, to evaluate the chemical formulation and downhole tool used to deploy the chemicals. Although the tool apparently functioned properly in the field test, the chemicals failed to expand sufficiently downhole, instead forming a dense polymer that may be ineffective in sealing loss zones. Subsequent laboratory tests conducted under simulated downhole conditions indicate that the foam chemical undergo sever mixing with water in the wellbore, which disturbs the kinetics of the chemical reaction more than was previously contemplated. The results indicate that without significant changes in the foam chemical formulation or delivery technique, the foam system will be ineffective in lost circulation control except under very favorable conditions. 4 refs., 6 figs., 2 tabs.

  1. Cellular Foams: A Potential Innovative Solid Breeder Material for Fusion Applications

    SciTech Connect (OSTI)

    Sharafat, S.; Ghoniem, N.; Williams, B.; Babcock, J. [University of California Los Angeles (United States)

    2005-05-15T23:59:59.000Z

    Ceramic foam and cellular materials are being used in a wide variety of industries and are finding ever growing number of applications. Over the past decade advances in manufacturing of cellular materials have resulted in ceramics with highly uniform interconnected porosities ranging in size from a few {mu}m to several mm. These relatively new ceramic foam materials have a unique set of thermo-mechanical properties, such as excellent thermal shock resistance and high surface to volume ratios. Based on new advances in processing ceramic foams, we suggest the development of ceramic foams or cellular ceramics for solid breeders in fusion reactor blankets. A cellular breeder material has a number of thermo-mechanical advantages over pebble beds, which can enhance blanket performance, improve operational stability, and reduce overall blanket costs.

  2. Foaming of E-Glass (Report for G Plus Project for PPG)

    E-Print Network [OSTI]

    Pilon, Laurent

    PNNL-14625 Foaming of E-Glass (Report for G Plus Project for PPG) D. Kim P.. Hrma Pacific Northwest for PPG) Dong-Sang Kim Pavel R. Hrma Pacific Northwest National Laboratory Bryan C. Dutton Laurent Pilon

  3. Foaming of E-Glass II (Report for G Plus Project for PPG)

    E-Print Network [OSTI]

    Pilon, Laurent

    P. R. Hrma Pacific Northwest National Laboratory L. Pilon University of California, Los Angeles Foaming of E-Glass II (Report for G Plus Project for PPG) D.-S. Kim M. Portch J. Matyas P. R. Hrma Pacific

  4. Novel application of foam for in-situ soil remediation. Topical report, April 1992-September 1993

    SciTech Connect (OSTI)

    Kilbane, J.J.; Liu, B.Y.; Conrad, J.R.; Srivastava, V.J.

    1997-08-01T23:59:59.000Z

    The objective of the task is to evaluate the use of foams to deliver surfactants, bacteria, solvents, and/or nutrients to promote in-situ bioremediation of soils contaminated with polynuclear aromatic hydrocarbons (PAHs) or to evaluate the use of foams to render contaminants available for physical collection and subsequent degradation. This task consists of two subtasks: (1) Literature Survey of Related Technologies and (2) Preliminary Experimental Investigations of Interfacial Phenomenon and the Use of Foams to Remediate Contaminated Sites. An extensive literature review was completed in which abstracts of more than one hundred technical articles were prepared. Laboratory studies to investigate the use of foams to remediate PAH-contaminated soil were performed with several Manufactured Gas Plant (MGP) soils as well as with model experimental systems.

  5. The Feasibility of Casting Sculpture in Kirksite

    E-Print Network [OSTI]

    Fox, Lewis Howard

    1968-01-01T23:59:59.000Z

    of equal parts of ammonium chloride and lithium n chloride. When soldering, use an 82.5 percent cadmium or 17.5 percent zinc solder with no flux.3 ē^ Metals Handbook. op. cit. , I, p. 1158. ^J. F. Lancaster. The Metallurgy of Welding, Brazing... Silver Chromium Gold These platings are most commonly applied for decorative purposes, but they also improve resistance to corrosion and abrasion. All plated coatings are somewhat porous; and, when moisture penetrates through the pores, some...

  6. FOAM FORMATION IN THE SALTSTONE PRODUCTION FACILITY: EVALUATION OF SOURCES AND MITIGATION

    SciTech Connect (OSTI)

    Cozzi, A.

    2011-01-18T23:59:59.000Z

    The Saltstone Production Facility receives waste from Tank 50H for treatment. Influents into Tank 50H include the Effluent Treatment Project waste concentrate, H-Canyon low activity waste and General Purpose Evaporator bottoms, Modular Caustic Side Solvent Extraction Unit decontaminated salt solution, and salt solution from the Deliquification, Dissolution and Adjust campaign. Using the Waste Characterization System (WCS), this study tracks the relative amounts of each influent into Tank 50H, as well as the total content of Tank 50H, in an attempt to identify the source of foaming observed in the Saltstone Production Facility hopper. Saltstone has been using antifoam as part of routine processing with the restart of the facility in December 2006. It was determined that the maximum admix usage in the Saltstone Production Facility, both antifoam and set retarder, corresponded with the maximum concentration of H-Canyon low activity waste in Tank 50H. This paper also evaluates archived salt solutions from Waste Acceptance Criteria analysis for propensity to foam and the antifoam dosage required to mitigate foaming. It was determined that Effluent Treatment Project contributed to the expansion factor (foam formation) and General Purpose Evaporator contributed to foaminess (persistence). It was also determined that undissolved solids contribute to foam persistence. It was shown that additions of Dow Corning Q2-1383a antifoam reduced both the expansion factor and foaminess of salt solutions. The evaluation of foaming in the grout hopper during the transition from water to salt solution indicated that higher water-to-premix ratios tended to produce increased foaming. It was also shown that additions of Dow Corning Q2-1383a antifoam reduced foam formation and persistence.

  7. Method and composition for molding low density desiccant syntactic foam articles

    DOE Patents [OSTI]

    Lula, James W. (Bonner Springs, KS); Schicker, James R. (Lee's Summit, MO)

    1984-01-01T23:59:59.000Z

    A method and a composition are provided for molding low density desiccant syntactic foam articles. A low density molded desiccant article may be made as a syntactic foam by blending a thermosetting resin, microspheres and molecular sieve desiccant powder, molding and curing. Such articles have densities of 0.2-0.9 g/cc, moisture capacities of 1-12% by weight, and can serve as light weight structural supports.

  8. Advanced geothermal foam drilling systems (AFS) -- Phase 1 final report, Part 1

    SciTech Connect (OSTI)

    W. C. Maurer

    1999-06-30T23:59:59.000Z

    An advanced coiled-tubing foam drilling system is being developed where two concentric strings of coiled tubing are used to convey water and air to the hole bottom where they are mixed together to produce foam for underbalanced drilling. This system has the potential to significantly reduce drilling costs by increasing drilling rates (due to the motor being powered by water), and reducing compressor and nitrogen costs (due to lower gas pressures and volumes).

  9. Metal inks

    DOE Patents [OSTI]

    Ginley, David S; Curtis, Calvin J; Miedaner, Alex; van Hest, Marinus Franciscus Antonius Maria; Kaydanova, Tatiana

    2014-02-04T23:59:59.000Z

    Self-reducing metal inks and systems and methods for producing and using the same are disclosed. In an exemplary embodiment, a method may comprise selecting metal-organic (MO) precursor, selecting a reducing agent, and dissolving the MO precursor and the reducing agent in an organic solvent to produce a metal ink that remains in a liquid phase at room temperature. Metal inks, including self-reducing and fire-through metal inks, are also disclosed, as are various applications of the metal inks.

  10. In-situ aging of roof systems containing polyisocyanurate roof insulation foamed with alternative blowing agents

    SciTech Connect (OSTI)

    Desjarlais, A.O.; Christian, J.E.; Graves, R.S.

    1993-10-01T23:59:59.000Z

    Experimental polyisocyanurate (PIR) foam roof insulations with permeable facers were installed in roofing systems and continuously monitored for thermal performance for four years. The foams were produced using a specific formulation that represented current technology in 1989 and were blown with CFC-11, HCFC-123, and HCFC-141b. These foams were installed in roof systems comprised of loosely-laid insulation boards covered by either a loosely-laid single ply white or black membrane. The in-situ testing was carried out on an outdoor test facility, the Roof Thermal Research Apparatus (RTRA). Additional specimens of these foams were aged in the laboratory and periodically evaluated using laboratory measurement equipment. This paper summarizes the in-situ data compiled to date, compares these data with the laboratory results, and examines whether the proposed laboratory procedure for accelerating the aging of foams by the slicing and scaling method accurately predicts the aging characteristics of these materials installed in roof systems. These experiments are part of a joint industry/government project established to evaluate the technical viability of alternative HCFC blowing agents for rigid closed-cell polyisocyanurate foam roof insulations. Members of the project are the US Department of Energy (DOE)/Oak Ridge National Laboratory (ORNL), the US Environmental Protection Agency (EPA), the Society of the Plastics Industry-Polyurethane Division (SPI), the Polyisocyanurate Insulation Manufacturers Association (PIMA), and the National Roofing Contractors Association (NRCA).

  11. Cellular morphology of organic-inorganic hybrid foams based on alkali alumino-silicate matrix

    SciTech Connect (OSTI)

    Verdolotti, Letizia; Capasso, Ilaria; Lavorgna, Marino [Institute of Composite and Biomedical Materials, National Research Council, Naples (Italy); Liguori, Barbara; Caputo, Domenico [Department of Chemical, Materials and Industrial Engineering, University of Naples Federico II, Naples (Italy); Iannace, Salvatore [Institute of Composite and Biomedical Materials, National Research Council, Naples, Italy and IMAST SCRAL, Piazza Bovio 22 Napoli 80133 (Italy)

    2014-05-15T23:59:59.000Z

    Organic-inorganic hybrid foams based on an alkali alumino-silicate matrix were prepared by using different foaming methods. Initially, the synthesis of an inorganic matrix by using aluminosilicate particles, activated through a sodium silicate solution, was performed at room temperature. Subsequently the viscous paste was foamed by using three different methods. In the first method, gaseous hydrogen produced by the oxidization of Si powder in an alkaline media, was used as blowing agent to generate gas bubbles in the paste. In the second method, the porous structure was generated by mixing the paste with a ďmeringueĒ type of foam previously prepared by whipping, under vigorous stirring, a water solution containing vegetal proteins as surfactants. In the third method, a combination of these two methods was employed. The foamed systems were consolidated for 24 hours at 40įC and then characterized by FTIR, X-Ray diffraction, scanning electron microscopy (SEM) and compression tests. Low density foams (?500 Kg/m{sup 3}) with good cellular structure and mechanical properties were obtained by combining the ďmeringueĒ approach with the use of the chemical blowing agent based on Si.

  12. Mechanical behavior of closed-cell and hollow-sphere metallic foams

    E-Print Network [OSTI]

    Sanders, Wynn Steven, 1974-

    2002-01-01T23:59:59.000Z

    (cont.) The elastic anisotropy and yield surfaces are fully characterized, and numerical equations are developed to allow the simple evaluation of the effect of geometric and material properties on the mechanical behavior ...

  13. Determination of bulk and entrance contributions to the pressure drop in metallic foams

    E-Print Network [OSTI]

    Medraj, Mamoun

    in the modified Darcy's equation as: V Kt p Ķ = (2) The hydraulic conductivity k of the original Equation 1 viscosity of the fluid [2]. Darcy's equation is only applicable when the velocity of the fluid. Measurements were done at velocities up to 20 m/s. The Hazen-Dupuit- Darcy permeability model was not able

  14. Silicone metalization

    DOE Patents [OSTI]

    Maghribi, Mariam N. (Livermore, CA); Krulevitch, Peter (Pleasanton, CA); Hamilton, Julie (Tracy, CA)

    2008-12-09T23:59:59.000Z

    A system for providing metal features on silicone comprising providing a silicone layer on a matrix and providing a metal layer on the silicone layer. An electronic apparatus can be produced by the system. The electronic apparatus comprises a silicone body and metal features on the silicone body that provide an electronic device.

  15. CASTING DEFECT MODELING IN AN INTEGRATED COMPUTATIONAL MATERIALS ENGINEERING APPROACH

    SciTech Connect (OSTI)

    Sabau, Adrian S [ORNL

    2015-01-01T23:59:59.000Z

    To accelerate the introduction of new cast alloys, the simultaneous modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components. The required models related to casting defects, such as microporosity and hot tears, are reviewed. Three aluminum alloys are considered A356, 356 and 319. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Examples are given for predicting microporosity defects and microstructure distribution for a plate casting. Models to predict fatigue life and yield stress are briefly highlighted here for the sake of completion and to illustrate how the length scales of the microstructure features as well as porosity defects are taken into account for modeling the mechanical properties. Thus, the data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. ACKNOWLEDGEMENTS This work was performed under a Cooperative Research and Development Agreement (CRADA) with the Nemak Inc., and Chrysler Co. for the project "High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines. The author would also like to thank Amit Shyam for reviewing the paper and Andres Rodriguez of Nemak Inc. Research sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Office, as part of the Propulsion Materials Program under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Part of this research was conducted through the Oak Ridge National Laboratory's High Temperature Materials Laboratory User Program, which is sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Program.

  16. Process for the fabrication of aluminum metallized pyrolytic graphite sputtering targets

    DOE Patents [OSTI]

    Makowiecki, Daniel M. (Livermore, CA); Ramsey, Philip B. (Livermore, CA); Juntz, Robert S. (Hayward, CA)

    1995-01-01T23:59:59.000Z

    An improved method for fabricating pyrolytic graphite sputtering targets with superior heat transfer ability, longer life, and maximum energy transmission. Anisotropic pyrolytic graphite is contoured and/or segmented to match the erosion profile of the sputter target and then oriented such that the graphite's high thermal conductivity planes are in maximum contact with a thermally conductive metal backing. The graphite contact surface is metallized, using high rate physical vapor deposition (HRPVD), with an aluminum coating and the thermally conductive metal backing is joined to the metallized graphite target by one of four low-temperature bonding methods; liquid-metal casting, powder metallurgy compaction, eutectic brazing, and laser welding.

  17. Tape-cast sensors and method of making

    DOE Patents [OSTI]

    Mukundan, Rangachary (Santa Fe, NM); Brosha, Eric L. (Los Alamos, NM); Garzon, Fernando H. (Santa Fe, NM)

    2009-08-18T23:59:59.000Z

    A method of making electrochemical sensors in which an electrolyte material is cast into a tape. Prefabricated electrodes are then partially embedded between two wet layers of the electrolyte tape to form a green sensor, and the green sensor is then heated to sinter the electrolyte tape around the electrodes. The resulting sensors can be used in applications such as, but not limited to, combustion control, environmental monitoring, and explosive detection. A electrochemical sensor formed by the tape-casting method is also disclosed.

  18. Use of duplex stainless steel castings in control valves

    SciTech Connect (OSTI)

    Gossett, J.L. [Fisher Controls International, Inc., Marshalltown, IA (United States)

    1996-07-01T23:59:59.000Z

    Duplex stainless steels have enjoyed rapidly increasing popularity in recent years. For numerous reasons the availability of these alloys in the cast form has lagged behind the availability of the wrought form. Commercial demand for control valves in these alloys has driven development of needed information to move into production. A systematic approach was used to develop specifications, suppliers and weld procedures. Corrosion, stress corrosion cracking (SCC), sulfide stress cracking (SSC) and hardness results are also presented for several alloys including; CD3MN (UNS J92205), CD4MCu (UNS J93370) and CD7MCuN (cast UNS S32550).

  19. Final report to the strategic environmental research and development program on near-net shape casting of uranium-6% niobium alloys

    SciTech Connect (OSTI)

    Gourdin, W.H.

    1996-01-01T23:59:59.000Z

    Fabrication methods traditionally used in the fabrication of depleted uranium parts within the Department of Energy (DOE) are extremely wasteful, with only 3% of the starting material actually appearing as finished product. The current effort, funded by the Strategic Environmental Research and Development Program (SERDP) at Los Alamos National Laboratory (LANL), Sandia National Laboratories, Albuquerque (SNLA), and Lawrence Livermore National Laboratory (LLNL), was conceived as a means to drastically reduce this inefficiency and the accompanying waste by demonstrating the technology to cast simple parts close to their final shape in molds made from a variety of materials. As a part of this coordinated study, LLNL was given, and has achieved, two primary objectives: (1) to demonstrate the feasibility of using refractory metal for reusable molds in the production of castings of uranium-6 wt% niobium alloy (U-6Nb); and (2) to demonstrate the utility of detailed simulations of thermal and fluid flow characteristics in the understanding and improvement of the near-net shape casting process. In both cases, our efforts were focused on a flat plate castings, which serve as simple prototypical parts. This report summarizes the results of LLNL work in each area.

  20. Improving the manufacturing yield of investment cast turbine blades through robust design

    E-Print Network [OSTI]

    Margetts, David (David Lawrence)

    2008-01-01T23:59:59.000Z

    The manufacturing of turbine blades is often outsourced to investment casting foundries by aerospace companies that design and build jet engines. Aerospace companies have found that casting defects are an important cost ...

  1. Construction and Preliminary HVS Tests of Pre-Cast Concrete Pavement Slabs

    E-Print Network [OSTI]

    Kohler, Erwin R.; du Plessis, Louw; Theyse, Hechter

    2008-01-01T23:59:59.000Z

    Cast Concrete Pavement Slabs with HVS Testing. Ē TechnicalCast Concrete Pavement Slabs with HVS Testing Signatures: E.subgrade. FWD testing on the centers of the concrete slabs

  2. Significant Energy and Material Reductions in the Continuous Casting of Certain Copper Alloys

    E-Print Network [OSTI]

    Nielson, W. D.

    This project addresses the continuous casting of barstock in certain copper alloys. A superheated reservoir of molten alloy is maintained in a continuously heated holding furnace (tundish) during casting. These tundishes are currently heated...

  3. Investigating Mould Heat Transfer in Thin Slab Casting with CON1D Begoa Santillana

    E-Print Network [OSTI]

    Thomas, Brian G.

    . Heat transfer in the thin slab casting mould is being investigated with the 1-D heat transfer model MODEL DESCRIPTION The heat transfer model, CON1D1 , models several aspects of the continuous casting

  4. CF8C PLus: A New Cast Stainless Steel for High-Temperature Diesel...

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

    CF8C PLus: A New Cast Stainless Steel for High-Temperature Diesel Exhaust Components CF8C PLus: A New Cast Stainless Steel for High-Temperature Diesel Exhaust Components...

  5. CF8C PLus: A New Cast Stainless Steel for High-Temperature Diesel...

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

    engine * Cast stainless upgrade for SiMo cast-iron diesel engine exhaust components turbo-housing exhaust manifold C-15, 14.6L HD On- Highway Diesel Engine Materials Need: High...

  6. alloy-graphite casting annual: Topics by E-print Network

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

    K; Zioutas, Konstantin; 10.1103PhysRevLett.94.121301 2005-01-01 412 The CERN Axion Solar Telescope (CAST): status and prospects Astrophysics (arXiv) Summary: The CAST...

  7. alloy-graphite castings technical: Topics by E-print Network

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

    K; Zioutas, Konstantin; 10.1103PhysRevLett.94.121301 2005-01-01 437 The CERN Axion Solar Telescope (CAST): status and prospects Astrophysics (arXiv) Summary: The CAST...

  8. Please cite this article in press as: Bourne, G.R., et al., Closed channel fabrication using micromolding of metallic glass. J. Mater. Process. Tech. (2009), doi:10.1016/j.jmatprotec.2008.12.003

    E-Print Network [OSTI]

    Sawyer, Wallace

    2009-01-01T23:59:59.000Z

    , Gainesville, FL 32611, USA b Department of Mechanical and Aerospace Engineering, University of Florida in molding, forming and casting of metallic glass alloys in a recent review (Schroers, 2005). The atomic structure of these alloys differentiates them from typical metals. While ordinary metals have a crystalline

  9. 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.

    casting machine, DCM, consists of basically four fundamental systems. These are the casting mold or die, the clamping unit, the injection unit, and the hydraulic system. Die casting molds perfonn two crucial functions; imparting the desired shape..., speeding the solidification process. The clamping unit is responsible for opening and closing the mold halves, as well as exerting the force that holds the two halves of the mold together during injection. Most die casting machines use a type...

  10. Efficient plasma production by intense laser irradiation of low density foam targets

    SciTech Connect (OSTI)

    Tripathi, S.; Chaurasia, S.; Munda, D. S.; Gupta, N. K.; Dhareshwar, L. J. [Laser and Neutron Physics Division, Bhabha Atomic Research Centre, Mumbai 85 (India); Nataliya, B. [Lebedev Physical Institute, Moscow (Russian Federation)

    2010-12-01T23:59:59.000Z

    Experimental investigations conducted on low density structured materials, such as foams have been presented in this paper. These low density foam targets having a density greater than the critical density of the laser produced plasma ({rho}{sub cr{approx_equal}}3 mg{center_dot}cm{sup -3} at laser wavelength 1.06 {mu}m) have been envisaged to have enhanced laser absorption. Experiments were done with an indigenously developed, focused 15 Joule/500 ps Nd: Glass laser at {lambda} = 1064 nm. The focused laser intensity on the target was in the range of I{approx_equal}10{sup 13}-2x10{sup 14} W/cm{sup 2}. Laser absorption was determined by energy balance experiments. Laser energy absorption was observed to be higher than 85%. In another set of experiments, low density carbon foam targets of density 150 mg/cc were compared with the solid carbon targets. The x-ray emission in the soft x-ray region was observed to increase in foam target by about 1.8 times and 2.3 times in carbon foam and Pt doped foam as compared to solid carbon. Further, investigations were also carried out to measure the energy transmitted through the sub-critical density TAC foam targets having a density less than 3 mg/cc. Such targets have been proposed to be used for smoothening of intensity ripples in a high power laser beam profile. Transmission exceeding 1.87% has been observed and consistent with results from other laboratories.

  11. SIMULATION OF STRESSES DURING CASTING OF BINARY MAGNESIUM-ALUMINUM ALLOYS M.G. Pokorny1

    E-Print Network [OSTI]

    Beckermann, Christoph

    SIMULATION OF STRESSES DURING CASTING OF BINARY MAGNESIUM-ALUMINUM ALLOYS M.G. Pokorny1 , C, Geesthacht, Germany Keywords: Magnesium Alloys, Casting, Stress Simulation Abstract A visco-plastic deformation model is used to predict thermal stresses during casting of binary Mg-Al alloys. The predictions

  12. Numerical Study of Steady Turbulent Flow through Bifurcated Nozzles in Continuous Casting

    E-Print Network [OSTI]

    Thomas, Brian G.

    . The effects of nozzle design and casting process operating variables on the jet characteristics exitingNumerical Study of Steady Turbulent Flow through Bifurcated Nozzles in Continuous Casting FADY M. NAJJAR, BRIAN G. THOMAS, and DONALD E. HERSHEY Bifurcated nozzles are used in continuous casting

  13. Edinburgh Research Explorer The Dalmarnock Fire Tests on a Cast Insitu Concrete Structure

    E-Print Network [OSTI]

    Millar, Andrew J.

    Edinburgh Research Explorer The Dalmarnock Fire Tests on a Cast Insitu Concrete Structure Citation Fire Tests on a Cast Insitu Concrete Structure'. in Proceedings of the international Workshop Fire THE DALMARNOCK FIRE TESTS ON A CAST INSITU CONCRETE STRUCTURE Susan Deeny PhD Student University of Edinburgh, UK

  14. Statistical analysis of the mechanical properties of thin walled ductile iron castings

    SciTech Connect (OSTI)

    Schrems, Karol K.; Hawk, Jeffrey A.; Dogan, Omer N.; Druschitz, A.P. (Intermet)

    2003-01-01T23:59:59.000Z

    Ductile iron castings have long been used in the automotive market. Ductile iron is inexpensive to produce and has desirable fracture resistance and mechanical properties. However, the weight of ductile iron is driving an effort to reduce wall thickness in order to increase fuel economy. Traditionally, cast iron has been cast into thick, bulky shapes. Reducing the section size of cast iron can be done, but pushes foundry practice into new areas. A consortium of foundries, foundry suppliers, and automotive manufacturers has been pursuing the use of thin walled ductile cast iron. This paper investigates the mechanical behavior of three experimental heats of thin-wall castings in order to evaluate property trends and limits. Castings as thin as 1.7 mm (0.07 in) have been successfully cast. The study was designed to investigate the effects of thickness and different casting heats on the dependent variables of ultimate tensile strength, yield strength, elongation-to-failure, reduction in area, and hardness. The ultimate tensile strength of the castings is found to increase as the casting thickness decreases. Conversely, the elongation-to-failure is found to decrease as the casting thickness decreases. Heat-to-heat differences were found, but they were usually within the scatter of the data.

  15. SURFACTANT BASED ENHANCED OIL RECOVERY AND FOAM MOBILITY CONTROL

    SciTech Connect (OSTI)

    George J. Hirasaki; Clarence A. Miller; Gary A. Pope; Richard E. Jackson

    2004-07-01T23:59:59.000Z

    Surfactant flooding has the potential to significantly increase recovery over that of conventional waterflooding. The availability of a large number of surfactants makes it possible to conduct a systematic study of the relation between surfactant structure and its efficacy for oil recovery. Also, the addition of an alkali such as sodium carbonate makes possible in situ generation of surfactant and significant reduction of surfactant adsorption. In addition to reduction of interfacial tension to ultra-low values, surfactants and alkali can be designed to alter wettability to enhance oil recovery. An alkaline surfactant process is designed to enhance spontaneous imbibition in fractured, oil-wet, carbonate formations. It is able to recover oil from dolomite core samples from which there was no oil recovery when placed in formation brine. Mobility control is essential for surfactant EOR. Foam is evaluted to improve the sweep efficiency of surfactant injected into fractured reservoirs. UTCHEM is a reservoir simulator specially designed for surfactant EOR. A dual-porosity version is demonstrated as a potential scale-up tool for fractured reservoirs.

  16. COSTS MODELS IN DESIGN AND MANUFACTURING OF SAND CASTING PRODUCTS

    E-Print Network [OSTI]

    Paris-Sud XI, Universitť de

    COSTS MODELS IN DESIGN AND MANUFACTURING OF SAND CASTING PRODUCTS Nicolas PERRY Ass. Prof., IRCCy.Bernard@irccyn.ec-nantes.fr Abstract: In the early phases of the product life cycle, the costs controls became a major decision tool difficulties, we will present an approach using a concept of cost entity related to the design and realization

  17. DIVISON 03 CONCRETE 03300 CAST-IN-PLACE CONCRETE

    E-Print Network [OSTI]

    -IN-PLACE CONCRETE A. Design Considerations 1. Testing and inspection will be required for cast-in-place concrete of the Building Code. All testing and inspection of concrete work will be contracted for and paid for directly by the University, regardless of building class. The A/E must specify all testing and inspection of concrete work

  18. The Dyslexia Foundation is Sponsoring a Web-Cast Conference

    E-Print Network [OSTI]

    The Dyslexia Foundation is Sponsoring a Web-Cast Conference The Dyslexia Foundation 4 Narragansett St./PO Box P-22 South Dartmouth, MA 02748 TheDyslexiaFoundation@gmail.com TheDyslexiaFoundation.org Reading/Literacy, Dyslexia and the Brain In Celebration of the 25th Anniversary of The Dyslexia Research

  19. Termination Casts: A Flexible Approach to Termination with General Recursion

    E-Print Network [OSTI]

    Weirich, Stephanie

    Termination Casts: A Flexible Approach to Termination with General Recursion Aaron Stump Computer distinguishes terminating terms and total functions from possibly diverging terms and partial functions type-form "Terminates t", expressing that term t is terminating; and then allow terms t to be coerced

  20. The Athlit ra: Classical and Hellenistic bronze casting

    E-Print Network [OSTI]

    Oron, Asaf

    2001-01-01T23:59:59.000Z

    half of the 10th century B. C. , are solid casts depicting a nude male with outstretched The earliest surviving examples of Greek sphyrelata are the figures of Apollo, Artemis, and Leto found at Dreros on Crete. The figures are currently dated...