National Library of Energy BETA

Sample records for glass metal casting

  1. Comparison of Structural Relaxation Behavior in As-Cast and Pre-Annealed Zr-Based Bulk Metallic Glasses Just below Glass Transition

    SciTech Connect (OSTI)

    Haruyama, Osami; Yoshikawa, Kazuyoshi; Yamazaki, Yoshikatsu; Yokoyama, Yoshihiko; Egami, Takeshi

    2015-04-25

    In this paper, the α-relaxation of pre-annealed Zr55Cu30Ni5Al10 bulk metallic glasses (BMGs) was compared with that of as-cast Zr-based BMGs including Zr55Cu30Ni5Al10. The α-relaxation was investigated by volume relaxation. The relaxation behavior was well described by a stretched exponential relaxation function, Φ (t) ≈ exp [ - (t/τ α )β α ], with the isothermal relaxation time, τα, and the Kohlrausch exponent, βα. The βα exhibited the strong temperature dependence for the pre-annealed BMG, while the weak temperature dependence was visualized for the as-cast BMG similar to the dynamic relaxation. The τα’s were modified by Moynihan and Narayanaswamy-Tool-Moynihan methods that reduce the difference in the thermal history of sample. Finally, as a result, the relaxation kinetics in the glass resembled that of a liquid deduced from the behavior of viscosity in the supercooled liquid.

  2. Comparison of Structural Relaxation Behavior in As-Cast and Pre-Annealed Zr-Based Bulk Metallic Glasses Just below Glass Transition

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

    Haruyama, Osami; Yoshikawa, Kazuyoshi; Yamazaki, Yoshikatsu; Yokoyama, Yoshihiko; Egami, Takeshi

    2015-04-25

    In this paper, the α-relaxation of pre-annealed Zr55Cu30Ni5Al10 bulk metallic glasses (BMGs) was compared with that of as-cast Zr-based BMGs including Zr55Cu30Ni5Al10. The α-relaxation was investigated by volume relaxation. The relaxation behavior was well described by a stretched exponential relaxation function, Φ (t) ≈ exp [ - (t/τ α )β α ], with the isothermal relaxation time, τα, and the Kohlrausch exponent, βα. The βα exhibited the strong temperature dependence for the pre-annealed BMG, while the weak temperature dependence was visualized for the as-cast BMG similar to the dynamic relaxation. The τα’s were modified by Moynihan and Narayanaswamy-Tool-Moynihan methods thatmore » reduce the difference in the thermal history of sample. Finally, as a result, the relaxation kinetics in the glass resembled that of a liquid deduced from the behavior of viscosity in the supercooled liquid.« less

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

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

    KB) More Documents & Publications ITP Metal Casting: Metalcasting Industry Technology Roadmap ITP Metal Casting: Implementation of Metal Casting Best Practices ITP Metal Casting: ...

  4. Clean Metal Casting

    SciTech Connect (OSTI)

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

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

  5. METAL PRODUCTION AND CASTING

    DOE Patents [OSTI]

    Magel, T.T.

    1958-03-01

    This patent covers a method and apparatus for collecting the molten metal produced by high temperature metal salt reduction. It consists essentially of subjecting the reaction vessel to centrifugal force in order to force the liberatcd molten metal into a coherent molten mass, and allowing it to solidify there. The apparatus is particularly suitable for use with small quantities of rare metals.

  6. EXELFS of Metallic Glasses

    SciTech Connect (OSTI)

    Ito, Y.; Alamgir, F.M.; Schwarz, R.B.; Jain, H.; Williams, D.B.

    1999-11-30

    The feasibility of using extended energy-loss fine structure (EXELFS) obtained from {approximately}1 nm regions of metallic glasses to study their short-range order has been examined. Ionization edges of the metallic glasses in the electron energy-loss spectrum (EELS) have been obtained from PdNiP bulk metallic glass and Ni{sub 2}P polycrystalline powder in a transmission electron microscope. The complexity of EXELFS analysis of L- and M-ionization edges of heavy elements (Z>22, i.e. Ni and Pd) is addressed by theoretical calculations using an ab initio computer code, and its results are compared with the experimental data.

  7. Method for casting thin metal objects

    SciTech Connect (OSTI)

    Pehrson, Brandon P; Moore, Alan F

    2015-04-14

    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.

  8. 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 (1.51 MB) More ...

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

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

    and Opportunities for the Metal Casting Industry | Department of Energy Advanced Melting Technologies: Energy Saving Concepts and Opportunities for the Metal Casting Industry ITP Metal Casting: Advanced Melting Technologies: Energy Saving Concepts and Opportunities for the Metal Casting Industry advancedmeltingtechnologies.pdf (1.83 MB) More Documents & Publications ITP Metal Casting: Theoretical/Best Practice Energy Use in Metalcasting Operations ITP Metal Casting: Energy and

  10. 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 ...

  11. Electronic structure of metallic glasses

    SciTech Connect (OSTI)

    Oelhafen, P.; Lapka, R.; Gubler, U.; Krieg, J.; DasGupta, A.; Guentherodt, H.J.; Mizoguchi, T.; Hague, C.; Kuebler, J.; Nagel, S.R.

    1981-01-01

    This paper is organized in six sections and deals with (1) the glassy transition metal alloys, their d-band structure, the d-band shifts on alloying and their relation to the alloy heat of formation (..delta..H) and the glass forming ability, (2) the glass to crystal phase transition viewed by valence band spectroscopy, (3) band structure calculations, (4) metallic glasses prepared by laser glazing, (5) glassy normal metal alloys, and (6) glassy hydrides.

  12. Light Metals Permanent Mold Casting

    SciTech Connect (OSTI)

    None

    2004-11-01

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

  13. Quinary metallic glass alloys

    DOE Patents [OSTI]

    Lin, X.; Johnson, W.L.

    1998-04-07

    At least quinary alloys form metallic glass upon cooling below the glass transition temperature at a rate less than 10{sup 3}K/s. Such alloys comprise zirconium and/or hafnium in the range of 45 to 65 atomic percent, titanium and/or niobium in the range of 4 to 7.5 atomic percent, and aluminum and/or zinc in the range of 5 to 15 atomic percent. The balance of the alloy compositions comprise copper, iron, and cobalt and/or nickel. The composition is constrained such that the atomic percentage of iron is less than 10 percent. Further, the ratio of copper to nickel and/or cobalt is in the range of from 1:2 to 2:1. The alloy composition formula is: (Zr,Hf){sub a}(Al,Zn){sub b}(Ti,Nb){sub c}(Cu{sub x}Fe{sub y}(Ni,Co){sub z}){sub d} wherein the constraints upon the formula are: a ranges from 45 to 65 atomic percent, b ranges from 5 to 15 atomic percent, c ranges from 4 to 7.5 atomic percent, d comprises the balance, d{hor_ellipsis}y is less than 10 atomic percent, and x/z ranges from 0.5 to 2.

  14. Quinary metallic glass alloys

    DOE Patents [OSTI]

    Lin, Xianghong; Johnson, William L.

    1998-01-01

    At least quinary alloys form metallic glass upon cooling below the glass transition temperature at a rate less than 10.sup.3 K/s. Such alloys comprise zirconium and/or hafnium in the range of 45 to 65 atomic percent, titanium and/or niobium in the range of 4 to 7.5 atomic percent, and aluminum and/or zinc in the range of 5 to 15 atomic percent. The balance of the alloy compositions comprise copper, iron, and cobalt and/or nickel. The composition is constrained such that the atomic percentage of iron is less than 10 percent. Further, the ratio of copper to nickel and/or cobalt is in the range of from 1:2 to 2:1. The alloy composition formula is: (Zr,Hf).sub.a (Al,Zn).sub.b (Ti,Nb).sub.c (Cu.sub.x Fe.sub.y (Ni,Co).sub.z).sub.d wherein the constraints upon the formula are: a ranges from 45 to 65 atomic percent, b ranges from 5 to 15 atomic percent, c ranges from 4 to 7.5 atomic percent, d comprises the balance, d.multidot.y is less than 10 atomic percent, and x/z ranges from 0.5 to 2.

  15. Horizontal electromagnetic casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, John R.; Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

    1987-01-01

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

  16. Horizontal electromagnetic casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, John R.; Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

    1988-01-01

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

  17. Energy use in selected metal casting facilities - 2003

    SciTech Connect (OSTI)

    Eppich, Robert E.

    2004-05-01

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

  18. ITP Metal Casting: Implementation of Metal Casting Best Practices

    Broader source: Energy.gov [DOE]

    The project examined cases where metal casters had implemented ITP research results and detailed the benefits they received due to that implementation.

  19. Spray casting of metallic preforms

    DOE Patents [OSTI]

    Flinn, John E.; Burch, Joseph V.; Sears, James W.

    2000-01-01

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

  20. Subcritical Measurements Multiple HEU Metal Castings

    SciTech Connect (OSTI)

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

    2008-01-01

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

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

    SciTech Connect (OSTI)

    None

    2000-12-01

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

  2. Chemical segregation in metallic glass nanowires

    SciTech Connect (OSTI)

    Zhang, Qi; Li, Mo; Li, Qi-Kai

    2014-11-21

    Nanowires made of metallic glass have been actively pursued recently due to the superb and unique properties over those of the crystalline materials. The amorphous nanowires are synthesized either at high temperature or via mechanical disruption using focused ion beam. These processes have potential to cause significant changes in structure and chemical concentration, as well as formation of defect or imperfection, but little is known to date about the possibilities and mechanisms. Here, we report chemical segregation to surfaces and its mechanisms in metallic glass nanowires made of binary Cu and Zr elements from molecular dynamics simulation. Strong concentration deviation are found in the nanowires under the conditions similar to these in experiment via focused ion beam processing, hot imprinting, and casting by rapid cooling from liquid state. Our analysis indicates that non-uniform internal stress distribution is a major cause for the chemical segregation, especially at low temperatures. Extension is discussed for this observation to multicomponent metallic glass nanowires as well as the potential applications and side effects of the composition modulation. The finding also points to the possibility of the mechanical-chemical process that may occur in different settings such as fracture, cavitation, and foams where strong internal stress is present in small length scales.

  3. Alloy with metallic glass and quasi-crystalline properties

    DOE Patents [OSTI]

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

    2004-02-17

    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.

  4. Volatile Species Retention During Metallic Fuel Casting

    SciTech Connect (OSTI)

    Randall S. Fielding; Douglas L. Proter

    2013-10-01

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

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

    SciTech Connect (OSTI)

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

    2009-04-01

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

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

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

    Use in Selected Metalcasting Facilities - 2003 ITP Metal Casting: Energy Use in Selected Metalcasting Facilities - 2003 energyuseinselectedmetalcasting52804.pdf (1.2 MB) More ...

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

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

    Corrosion Testing Practices - High Alloy Corrosion Program ITP Metal Casting: Corrosion Testing Practices - High Alloy Corrosion Program lehighfs.pdf (151.33 KB) More Documents & ...

  8. ITP Metal Casting: Metalcasting Industry Technology Roadmap

    Broader source: Energy.gov [DOE]

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

  9. Production of glass or glass-ceramic to metal seals with the application of pressure

    DOE Patents [OSTI]

    Kelly, Michael D.; Kramer, Daniel P.

    1987-11-10

    In a process for preparing a glass or glass-ceramic to metal seal comprising contacting the glass with the metal and heat-treating the glass and metal under conditions whereby the glass to metal seal is effected and, optionally, the glass is converted to a glass-ceramic, an improvement comprises carrying out the heat-treating step using hot isostatic pressing.

  10. Production of glass or glass-ceramic to metal seals with the application of pressure

    DOE Patents [OSTI]

    Kelly, M.D.; Kramer, D.P.

    1985-01-04

    In a process for preparing a glass or glass-ceramic to metal seal comprising contacting the glass with the metal and heat-treating the glass and metal under conditions whereby the glass to metal seal is effected and, optionally, the glass is converted to a glass-ceramic, an improvement comprises carrying out the heat-treating step using hot isostatic pressing.

  11. Method and mold for casting thin metal objects

    SciTech Connect (OSTI)

    Pehrson, Brandon P; Moore, Alan F

    2014-04-29

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

  12. Metallic Fuel Casting Development and Parameter Optimization Simulations

    SciTech Connect (OSTI)

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

    2013-03-01

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

  13. Filler metal alloy for welding cast nickel aluminide alloys

    DOE Patents [OSTI]

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

    1998-03-10

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

  14. Mold with improved core for metal casting operation

    DOE Patents [OSTI]

    Gritzner, Verne B.; Hackett, Donald W.

    1977-01-01

    The present invention is directed to a mold containing an improved core for use in casting hollow, metallic articles. The core is formed of, or covered with, a layer of cellular material which possesses sufficient strength to maintain its structural integrity during casting, but will crush to alleviate the internal stresses that build up if the normal contraction during solidification and cooling is restricted.

  15. Metal and Glass Manufacturers Reduce Costs by Increasing Energy...

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

    Metal and Glass Manufacturers Reduce Costs by Increasing Energy Efficiency in Process Heating Systems Metal and Glass Manufacturers Reduce Costs by Increasing Energy Efficiency in...

  16. ITP Metal Casting: Corrosion Testing Practices – High Alloy Corrosion Program

    Broader source: Energy.gov [DOE]

    This subtask under ESMARRT Material properties for Casting or Tooling Design Improvement supports the industry objectives of Designings for New Markets and Improved Metal Casting Processes.

  17. Fluxing agent for metal cast joining

    DOE Patents [OSTI]

    Gunkel, Ronald W.; Podey, Larry L.; Meyer, Thomas N.

    2002-11-05

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

  18. Electromagnetic augmentation for casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, J.R.

    1987-10-28

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

  19. Fabrication of metallic glass structures

    DOE Patents [OSTI]

    Cline, C.F.

    1983-10-20

    Amorphous metal powders or ribbons are fabricated into solid shapes of appreciable thickness by the application of compaction energy. The temperature regime wherein the amorphous metal deforms by viscous flow is measured. The metal powders or ribbons are compacted within the temperature regime.

  20. Bioactive glass coatings for orthopedic metallic implants

    SciTech Connect (OSTI)

    Lopez-Esteban, Sonia; Saiz, Eduardo; Fujino, Sigheru; Oku, Takeo; Suganuma, Katsuaki; Tomsia, Antoni P.

    2003-06-30

    The objective of this work is to develop bioactive glass coatings for metallic orthopedic implants. A new family of glasses in the SiO2-Na2O-K2O-CaO-MgO-P2O5 system has been synthesized and characterized. The glass properties (thermal expansion, softening and transformation temperatures, density and hardness) are in line with the predictions of established empirical models. The optimized firing conditions to fabricate coatings on Ti-based and Co-Cr alloys have been determined and related to the glass properties and the interfacial reactions. Excellent adhesion to alloys has been achieved through the formation of 100-200 nm thick interfacial layers (Ti5Si3 on Ti-based alloys and CrOx on Co-Cr). Finally, glass coatings, approximately 100 mu m thick, have been fabricated onto commercial Ti alloy-based dental implants.

  1. Structural rejuvenation in bulk metallic glasses

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

    Tong, Yang; Iwashita, T.; Dmowski, Wojciech; Bei, Hongbin; Yokoyama, Y.; Egami, Takeshi

    2015-01-05

    Using high-energy X-ray diffraction we study structural changes in bulk metallic glasses after uniaxial compressive homogeneous deformation at temperatures slightly below the glass transition. We observe that deformation results in structural disordering corresponding to an increase in the fictive, or effective, temperature. However, the structural disordering saturates after yielding. Lastly, examination of the experimental structure and molecular dynamics simulation suggests that local changes in the atomic connectivity network are the main driving force of the structural rejuvenation.

  2. CASTING SLIPS FOR FABRICATION OF REFRACTORY METAL WARE

    DOE Patents [OSTI]

    Stoddard, S.D.; Nuckolls, D.E.; Cowan, R.E.

    1962-09-01

    A composition is given for slip casting tungsten metal. The composition consists essentially of tungsten metal with an average particle size of 0.9 micron, an organic vehicle such as methyl chloroform, o-xylene, n-butyl acetate, isobutyl acetate, and 1, 1, 2, 2-tetrachlorethane, and a suspending agent such as ethyl cellulose, with the approximate ratio of said vehicle to the tungsten metal being 12 cc of a solution containing from 5 to about 20 grams of said ethyl cellulose in 400 cc of said organic vehicle per 100 grams of metal. (AEC)

  3. Implementation of Metal Casting Best Practices

    SciTech Connect (OSTI)

    Eppich, Robert; Naranjo, Robert D.

    2007-01-01

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

  4. Filler metal alloy for welding cast nickel aluminide alloys

    DOE Patents [OSTI]

    Santella, Michael L.; Sikka, Vinod K.

    1998-01-01

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

  5. Cooling system for continuous metal casting machines

    DOE Patents [OSTI]

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

    1988-06-07

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

  6. Cooling system for continuous metal casting machines

    DOE Patents [OSTI]

    Draper, Robert; Sumpman, Wayne C.; Baker, Robert J.; Williams, Robert S.

    1988-01-01

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

  7. Electromagnetic augmentation for casting of thin metal sheets

    DOE Patents [OSTI]

    Hull, John R.

    1989-01-01

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

  8. Method for forming glass-to-metal seals

    DOE Patents [OSTI]

    Kramer, Daniel P.; Massey, Richard T.

    1986-01-01

    A method for forming a glass-to-metal seal in which the glass has a higher melting point than the metal. The molten glass is vacuum injection molded onto the metal, thus melting a very thin layer of the surface of the metal long enough to form a seal, but not long enough to cause a distortion in the shape of the metal component.

  9. Method for forming glass-to-metal seals

    DOE Patents [OSTI]

    Kramer, D.P.; Massey, R.T.

    1985-08-26

    Disclosed is a method for forming a glass-to-metal seal in which the glass has a higher melting point than the metal. The molten glass is vacuum injection molded onto the metal, thus melting a very thin layer of the surface of the metal long enough to form a seal, but not long enough to cause a distortion in the shape of the metal component.

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

    SciTech Connect (OSTI)

    None

    2002-05-01

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

  11. Melt-cast organic glasses as high-efficiency fast neutron scintillators

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

    Carlson, Joseph S.; Feng, Patrick L.

    2016-06-24

    In this work we report a new class of organic-based scintillators that combines several of the desirable attributes of existing crystalline, liquid, and plastic organic scintillators. The prepared materials may be isolated in single crystalline form or melt-cast to produce highly transparent glasses that have been shown to provide high light yields of up to 16,000 photons/MeVee, as evaluated against EJ-200 plastic scintillators and solution-grown trans-stilbene crystals. The prepared organic glasses exhibit neutron/gamma pulse-shape discrimination (PSD) and are compatible with wavelength shifters to reduce optical self-absorption effects that are intrinsic to pure materials such as crystalline organics. In conclusion, themore » combination of high scintillation efficiency, PSD capabilities, and facile scale-up via melt-casting distinguishes this new class of amorphous materials from existing alternatives.« less

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

    SciTech Connect (OSTI)

    Margolis, Nancy; Jamison, Keith; Dove, Louise

    1999-09-01

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

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

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

    TheoreticalBest Practice Energy Use in Metalcasting Operations ITP Metal Casting: TheoreticalBest Practice Energy Use in Metalcasting Operations doebestpractice052804.pdf (1.64 ...

  14. Electromagnetic confinement for vertical casting or containing molten metal

    DOE Patents [OSTI]

    Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

    1991-01-01

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

  15. Sink property of metallic glass free surfaces

    SciTech Connect (OSTI)

    Shao, Lin; Fu, Engang; Price, Lloyd; Chen, Di; Chen, Tianyi; Wang, Yongqiang; Xie, Guoqiang; Lucca, Don A.

    2015-03-16

    When heated to a temperature close to glass transition temperature, metallic glasses (MGs) begin to crystallize. Under deformation or particle irradiation, crystallization occurs at even lower temperatures. Hence, phase instability represents an application limit for MGs. Here, we report that MG membranes of a few nanometers thickness exhibit properties different from their bulk MG counterparts. The study uses in situ transmission electron microscopy with concurrent heavy ion irradiation and annealing to observe crystallization behaviors of MGs. For relatively thick membranes, ion irradiations introduce excessive free volumes and thus induce nanocrystal formation at a temperature linearly decreasing with increasing ion fluences. For ultra-thin membranes, however, the critical temperature to initiate crystallization is about 100 K higher than the bulk glass transition temperature. Molecular dynamics simulations indicate that this effect is due to the sink property of the surfaces which can effectively remove excessive free volumes. These findings suggest that nanostructured MGs having a higher surface to volume ratio are expected to have higher crystallization resistance, which could pave new paths for materials applications in harsh environments requiring higher stabilities.

  16. Sink property of metallic glass free surfaces

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

    Shao, Lin; Fu, Engang; Price, Lloyd; Chen, Di; Chen, Tianyi; Wang, Yongqiang; Xie, Guoqiang; Lucca, Don A.

    2015-03-16

    When heated to a temperature close to glass transition temperature, metallic glasses (MGs) begin to crystallize. Under deformation or particle irradiation, crystallization occurs at even lower temperatures. Hence, phase instability represents an application limit for MGs. Here, we report that MG membranes of a few nanometers thickness exhibit properties different from their bulk MG counterparts. The study uses in situ transmission electron microscopy with concurrent heavy ion irradiation and annealing to observe crystallization behaviors of MGs. For relatively thick membranes, ion irradiations introduce excessive free volumes and thus induce nanocrystal formation at a temperature linearly decreasing with increasing ion fluences.more » For ultra-thin membranes, however, the critical temperature to initiate crystallization is about 100 K higher than the bulk glass transition temperature. Molecular dynamics simulations indicate that this effect is due to the sink property of the surfaces which can effectively remove excessive free volumes. These findings suggest that nanostructured MGs having a higher surface to volume ratio are expected to have higher crystallization resistance, which could pave new paths for materials applications in harsh environments requiring higher stabilities.« less

  17. Sink property of metallic glass free surfaces

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

    Shao, Lin; Fu, Engang; Price, Lloyd; Chen, Di; Chen, Tianyi; Wang, Yongqiang; Xie, Guoqiang; Lucca, Don A.

    2015-03-16

    When heated to a temperature close to glass transition temperature, metallic glasses (MGs) begin to crystallize. Under deformation or particle irradiation, crystallization occurs at even lower temperatures. Hence, phase instability represents an application limit for MGs. Here, we report that MG membranes of a few nanometers thickness exhibit properties different from their bulk MG counterparts. The study uses in situ transmission electron microscopy with concurrent heavy ion irradiation and annealing to observe crystallization behaviors of MGs. For relatively thick membranes, ion irradiations introduce excessive free volumes and thus induce nanocrystal formation at a temperature linearly decreasing with increasing ion fluences.moreFor ultra-thin membranes, however, the critical temperature to initiate crystallization is about 100 K higher than the bulk glass transition temperature. Molecular dynamics simulations indicate that this effect is due to the sink property of the surfaces which can effectively remove excessive free volumes. These findings suggest that nanostructured MGs having a higher surface to volume ratio are expected to have higher crystallization resistance, which could pave new paths for materials applications in harsh environments requiring higher stabilities.less

  18. Economic manufacturing of bulk metallic glass compositions by microalloying

    DOE Patents [OSTI]

    Liu, Chain T.

    2003-05-13

    A method of making a bulk metallic glass composition includes the steps of:a. providing a starting material suitable for making a bulk metallic glass composition, for example, BAM-11; b. adding at least one impurity-mitigating dopant, for example, Pb, Si, B, Sn, P, to the starting material to form a doped starting material; and c. converting the doped starting material to a bulk metallic glass composition so that the impurity-mitigating dopant reacts with impurities in the starting material to neutralize deleterious effects of the impurities on the formation of the bulk metallic glass composition.

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

    SciTech Connect (OSTI)

    Gwyn, Mike

    2009-03-31

    The Cast Metals Coalition (CMC) partnership program was funded to ensure that the results of the Department of Energy's (DOE) metalcasting research and development (R&D) projects are successfully deployed into industry. Specifically, the CMC program coordinated the transfer and deployment of energy saving technologies and process improvements developed under separately funded DOE programs and projects into industry. The transition of these technologies and process improvements is a critical step in the path to realizing actual energy savings. At full deployment, DOE funded metalcasting R&D results are projected to save 55% of the energy used by the industry in 1998. This closely aligns with DOE's current goal of driving a 25% reduction in industrial energy intensity by 2017. In addition to benefiting DOE, these energy savings provide metalcasters with a significant economic advantage. Deployment of already completed R&D project results and those still underway is estimated to return over 500% of the original DOE and industry investment. Energy savings estimates through December 2008 from the Energy-Saving Melting and Revert Reduction Technology (E-SMARRT) portfolio of projects alone are 12 x 1012 BTUs, with a projection of over 50 x 1012 BTUs ten years after program completion. These energy savings and process improvements have been made possible through the unique collaborative structure of the CMC partnership. The CMC team consists of DOE's Office of Industrial Technology, the three leading metalcasting technical societies in the U.S: the American Foundry Society; the North American Die Casting Association; and the Steel Founders Society of America; and the Advanced Technology Institute (ATI), a recognized leader in distributed technology management. CMC provides collaborative leadership to a complex industry composed of approximately 2,100 companies, 80% of which employ less than 100 people, and only 4% of which employ more than 250 people. Without collaboration

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

    SciTech Connect (OSTI)

    Jensen, D.

    1994-06-01

    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.

  1. Ductility and work hardening in nano-sized metallic glasses

    SciTech Connect (OSTI)

    Chen, D. Z.; Gu, X. W.; An, Q.; Goddard, W. A.; Greer, J. R.

    2015-02-09

    In-situ nano-tensile experiments on 70 nm-diameter free-standing electroplated NiP metallic glass nanostructures reveal tensile true strains of ∼18%, an amount comparable to compositionally identical 100 nm-diameter focused ion beam samples and ∼3 times greater than 100 nm-diameter electroplated samples. Simultaneous in-situ observations and stress-strain data during post-elastic deformation reveal necking and work hardening, features uncharacteristic for metallic glasses. The evolution of free volume within molecular dynamics-simulated samples suggests a free surface-mediated relaxation mechanism in nano-sized metallic glasses.

  2. Process for direct conversion of reactive metals to glass

    DOE Patents [OSTI]

    Rajan, John B.; Kumar, Romesh; Vissers, Donald R.

    1990-01-01

    Radioactive alkali metal is introduced into a cyclone reactor in droplet form by an aspirating gas. In the cyclone metal reactor the aspirated alkali metal is contacted with silica powder introduced in an air stream to form in one step a glass. The sides of the cyclone reactor are preheated to ensure that the initial glass formed coats the side of the reactor forming a protective coating against the reactants which are maintained in excess of 1000.degree. C. to ensure the formation of glass in a single step.

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

    DOE Patents [OSTI]

    Meyer, Thomas N.

    2004-06-01

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

  4. Ammonia-treated phosphate glasses useful for sealing to metals

    DOE Patents [OSTI]

    Brow, R.K.; Day, D.E.

    1991-09-03

    A method of improving surface-dependent properties of phosphate glass such as durability and wear resistance without significantly affecting its thermal expansion coefficient is provided which comprises annealing the glass in a dry ammonia atmosphere at temperatures approximating the transition temperature of the glass. The ammonia annealing treatment of the present invention is carried out for a time sufficient to allow incorporation of a thin layer of nitrogen into the surface of the phosphate glass, and the treatment improves the durability of the glass without the reduction in the thermal expansion coefficient that has restricted the effectiveness of prior ammonia treatments. The improved phosphate glass resulting from this method is superior in wear resistance, yet maintains suitable thermal expansion properties so that it may be used effectively in a variety of applications requiring hermetic glass-metal seals.

  5. Structure and constitution of glass and steel compound in glass-metal composite

    SciTech Connect (OSTI)

    Lyubimova, Olga N.; Morkovin, Andrey V.; Dryuk, Sergey A.; Nikiforov, Pavel A.

    2014-11-14

    The research using methods of optical and scanning electronic microscopy was conducted and it discovered common factors on structures and diffusing zone forming after welding glass C49-1 and steel Ct3sp in technological process of creating new glass-metal composite. Different technological modes of steel surface preliminary oxidation welded with and without glass were investigated. The time of welding was varied from minimum encountering time to the time of stabilizing width of diffusion zone.

  6. Metallic glass composition. [That does not embrittle upon annealing

    DOE Patents [OSTI]

    Kroeger, D.M.; Koch, C.C.

    1984-09-14

    This patent pertains to a metallic glass alloy that is either iron-based or nickel-based or based on a mixture of iron and nickel, containing lesser amounts of elements selected from the group boron, silicon, carbon and phosphorous to which is added an amount of a ductility-enhancing element selected from the group cerium, lanthanum, praseodymium and neodymium sufficient to increase ductility of the metallic glass upon annealing.

  7. Ceramic-glass-metal seal by microwave heating

    DOE Patents [OSTI]

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

    1983-10-04

    A method for producing a ceramic-glass-metal seal by microwaving, mixes a slurry of glass sealing material and coupling agent and applies same to ceramic and metal workpieces. The slurry and workpieces are then insulated and microwaved at a power, time and frequency sufficient to cause a liquid-phase reaction in the slurry. The reaction of the glass sealing material forms a chemically different seal than that which would be formed by conventional heating because it is formed by diffusion rather than by wetting of the reactants.

  8. Ceramic-glass-metal seal by microwave heating

    DOE Patents [OSTI]

    Meek, Thomas T.; Blake, Rodger D.

    1985-01-01

    A method for producing a ceramic-glass-metal seal by microwaving mixes a slurry of glass sealing material and coupling agent and applies same to ceramic and metal workpieces. The slurry and workpieces are then insulated and microwaved at a power, time and frequency sufficient to cause a liquid phase reaction in the slurry. The reaction of the glass sealing material forms a chemically different seal than that which would be formed by conventional heating because it is formed by diffusion rather than by wetting of the reactants.

  9. Glass ceramic-to-metal seals

    DOE Patents [OSTI]

    Not Available

    1982-04-19

    A glass ceramic composition prepared by subjecting a glass composition comprising, by weight, 65 to 80% SiO/sub 2/, 8 to 16% Li/sub 2/O, 2 to 8% Al/sub 2/O/sub 3/, 1 to 8% K/sub 2/O, 1 to 5% P/sub 2/O/sub 5/ and 1.5 to 7% B/sub 2/O/sub 3/, to the following processing steps of heating the glass composition to a temperature sufficient to crystallize lithium metasilicate therein, holding the glass composition at a temperature and for a time period sufficient to dissolve the lithium metasilicate therein thereby creating cristobalite nucleii, cooling the glass composition and maintaining the composition at a temperature and for a time period sufficient to recrystallize lithium metasilicate therein, and thermally treating the glass composition at a temperature and for a time period sufficient to caus growth of cristobalite and further crystallization of lithium metasilicate producing a glass ceramic composition having a specific thermal expansion coefficient and products containing said composition.

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

    SciTech Connect (OSTI)

    Fasoyinu, Yemi

    2014-03-31

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

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

    Broader source: Energy.gov [DOE]

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

  12. High strength glass-ceramic to metal seals

    SciTech Connect (OSTI)

    Haws, L D; Kramer, D P; Moddeman, W E; Wooten, G W

    1986-12-01

    In many applications, ceramics are joined to other materials, especially metals. In such cases, interfacial strength is as important as the strength of each constituent material. Examples are presented for tailoring materials and processes to optimize the glass-ceramic-to-metal seal. Means for detecting defects, nondestructively, are also identified.

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

    DOE Patents [OSTI]

    Trudel, David R.; Meyer, Thomas N.; Kinosz, Michael J.; Arnaud, Guy; Bigler, Nicolas

    2003-06-17

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

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

    SciTech Connect (OSTI)

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

    2001-12-14

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

  15. Synthesis of new amorphous metallic spin glasses

    DOE Patents [OSTI]

    Haushalter, R.C.

    1985-02-11

    Disclosed are: amorphous metallic precipitates having the formula (M/sub 1/)/sub a/(M/sub 2/)/sub b/ wherein M/sub 1/ is at least one transition metal, M/sub 2/ is at least one main group metal and the integers ''a'' and ''b'' provide stoichiometric balance; the precipitates having a degree of local order characteristic of chemical compounds from the precipitation process and useful electrical and mechanical properties.

  16. Synthesis of new amorphous metallic spin glasses

    DOE Patents [OSTI]

    Haushalter, Robert C.

    1988-01-01

    Amorphous metallic precipitates having the formula (M.sub.1).sub.a (M.sub.2).sub.b wherein M.sub.1 is at least one transition metal, M.sub.2 is at least one main group metal and the integers "a" and "b" provide stoichiometric balance; the precipitates having a degree of local order characteristic of chemical compounds from the precipitation process and useful electrical and mechanical properties.

  17. Synthesis of new amorphous metallic spin glasses

    DOE Patents [OSTI]

    Haushalter, Robert C.

    1986-01-01

    Amorphous metallic precipitates having the formula (M.sub.1).sub.a (M.sub.2).sub.b wherein M.sub.1 is at least one transition metal, M.sub.2 is at least one main group metal and the integers "a" and "b" provide stoichiometric balance; the precipitates having a degree of local order characteristic of chemical compounds from the precipitation process and useful electrical and mechanical properties.

  18. Soldering of Thin Film-Metallized Glass Substrates

    SciTech Connect (OSTI)

    Hosking, F.M.; Hernandez, C.L.; Glass, S.J.

    1999-03-31

    The ability to produce reliable electrical and structural interconnections between glass and metals by soldering was investigated. Soldering generally requires premetallization of the glass. As a solderable surface finish over soda-lime-silicate glass, two thin films coatings, Cr-Pd-Au and NiCr-Sn, were evaluated. Solder nettability and joint strengths were determined. Test samples were processed with Sn60-Pb40 solder alloy at a reflow temperature of 210 C. Glass-to-cold rolled steel single lap samples yielded an average shear strength of 12 MPa. Solder fill was good. Control of the Au thickness was critical in minimizing the formation of AuSn{sub 4} intermetallic in the joint, with a resulting joint shear strength of 15 MPa. Similar glass-to-glass specimens with the Cr-Pd-Au finish failed at 16.5 MPa. The NiCr-Sn thin film gave even higher shear strengths of 20-22.5 MPa, with failures primarily in the glass.

  19. Ammonia-treated phosphate glasses useful for sealing to metals metals

    DOE Patents [OSTI]

    Brow, Richard K.; Day, Delbert E.

    1991-01-01

    A method of improving surface-dependent properties of phosphate glass such as durability and wear resistance without significantly affecting its thermal expansion coefficient is provided which comprises annealing the glass in a dry ammonia atmosphere at temperatures approximating the transition temperature of the glass. The ammonia annealing treatment of the present invention is carried out for a time sufficient to allow incorporation of a thin layer of nitrogen into the surface of the phosphate glass, and the treatment improves the durability of the glass without the reduction in the thermal expansion coefficient that has restricted the effectiveness of prior ammonia treatments. The improved phosphate glass resulting from this method is superior in wear resistance, yet maintains suitable thermal expansion properties so that it may be used effectively in a variety of applications requiring hermetic glass-metal seals.

  20. Metallic glass could make your next cell phone harder to break

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

    Metallic glass could make your next cell phone harder to break Alumni Link: Opportunities, News and Resources for Former Employees Latest Issue:September 2015 all issues All Issues » submit Metallic glass could make your next cell phone harder to break Lab researcher works to rearrange the atoms in metals June 20, 2014 New insights to changing the atomic structure of metals New insights to changing the atomic structure of metals Contact Linda Anderman Email Metal and glass objects are all

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

    SciTech Connect (OSTI)

    Ogata, Takanari; Tsukada, Takeshi

    2007-07-01

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

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

    SciTech Connect (OSTI)

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

    2004-10-01

    The utilization of aluminum die casting as enclosures where internal equipment is rotating inside of the casting and could fracture requires a strong housing to restrain the fractured parts. A typical example would be a supercharger. In case of a failure, unless adequately contained, fractured parts could injure people operating the equipment. A number of potential reinforcement materials were investigated. The initial work was conducted in sand molds to create experimental conditions that promote prolonged contact of the reinforcing material with molten aluminum. Bonding of Aluminum bronze, Cast iron, and Ni-resist inserts with various electroplated coatings and surface treatments were analyzed. Also toughening of A354 aluminum cast alloy by steel and stainless steel wire mesh with various conditions was analyzed. A practical approach to reinforcement of die cast aluminum components is to use a reinforcing steel preform. Such performs can be fabricated from steel wire mesh or perforated metal sheet by stamping or deep drawing. A hemispherical, dome shaped casting was selected in this investigation. A deep drawing die was used to fabricate the reinforcing performs. The tendency of aluminum cast enclosures to fracture could be significantly reduced by installing a wire mesh of austenitic stainless steel or a punched austenitic stainless steel sheet within the casting. The use of reinforcements made of austenitic stainless steel wire mesh or punched austenitic stainless steel sheet provided marked improvement in reducing the fragmentation of the casting. The best strengthening was obtained with austenitic stainless steel wire and with a punched stainless steel sheet without annealing this material. Somewhat lower results were obtained with the annealed punched stainless steel sheet. When the annealed 1020 steel wire mesh was used, the results were only slightly improved because of the lower mechanical properties of this unalloyed steel. The lowest results were

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

    DOE Patents [OSTI]

    Kuznetsov, Stephen B.

    1986-01-01

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

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

    DOE Patents [OSTI]

    Kuznetsov, S.B.

    1986-04-01

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

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

    SciTech Connect (OSTI)

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

    2007-09-01

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

  6. ‘Crystal Genes’ in Metallic Liquids and Glasses

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

    Sun, Yang; Zhang, Feng; Ye, Zhuo; Zhang, Yue; Fang, Xiaowei; Ding, Zejun; Wang, Cai-Zhuang; Mendelev, Mikhail I.; Ott, Ryan T.; Kramer, Matthew J.; et al

    2016-03-31

    We analyze the underlying structural order that transcends liquid, glass and crystalline states in metallic systems. A genetic algorithm is applied to search for the most common energetically favorable packing motifs in crystalline structures. These motifs are in turn compared to the observed packing motifs in the actual liquid or glass structures using a cluster-alignment method. Using this method, we have revealed the nature of the short-range order in Cu64Zr36 glasses. More importantly, we identified a novel structural order in the Al90Sm10 system. In addition, our approach brings new insight into understanding the origin of vitrification and describing mesoscopic order-disordermore » transitions in condensed matter systems.« less

  7. Melting, Solidification, Remelting, and Separation of Glass and Metal

    SciTech Connect (OSTI)

    M. A. Ebadian; R. C.Xin; Z. F. Dong

    1998-11-02

    Several kinds of radioactive waste exist in mixed forms at DOE sites throughout the United States. These Wastes consist of radionuclides and some usefil bme materials. One purpose of waste treatment technologies is to vitrify the radionuclides into durable, stable glass-like materials to reduce the size of the waste form requiring final disposal. The other purpose is to recycle and reuse most of the usefi.d base materials. Thus, improved techniques for the separation of molten metal and glass are essential. Several high temperature vitrification technologies have been developed for the treatment of a wide range of mixed waste types in both the low-level waste and transuranic (TRU) mixed waste categories currently in storage at DOE sites throughout the nation. These processes include the plasma hearth process, which is being developed by Science Applications International Corporation (SAIC), and the arc melter vitrification process, which is being developed at Idaho National Engineering Laboratory. The products of these processes are an oxide slag phase and a reduced metal phase. The metal phase has the potential to be recycled within the DOE Complex. Enhanced slag/metal separation methods are needed to suppoti these process. A separation method is also needed for the radioactively contaminated scrap metal recycling processe; in order to obtain highly refined recycled metals.

  8. On the correlation between microscopic structural heterogeneity and embrittlement behavior in metallic glasses

    SciTech Connect (OSTI)

    Li, Weidong; Gao, Yanfei; Bei, Hongbin

    2015-10-05

    To establish a relationship between microstructure and mechanical properties, we systematically annealed a Zr-based bulk metallic glass (BMG) at 100 ~ 300°C and measured their mechanical and thermal properties. The as-cast BMG exhibits some ductility, while the increase of annealing temperature and time leads to the transition to a brittle behavior that can reach nearly-zero fracture energy. The differential scanning calorimetry did not find any significant changes in crystallization temperature and enthalpy, indicating that the materials still remained fully amorphous. Elastic constants measured by ultrasonic technique vary only slightly with respect to annealing temperature and time, which does obey the empirical relationship between Poisson’s ratio and fracture behavior. Nanoindentation pop-in tests were conducted, from which the pop-in strength mapping provides a “mechanical probe” of the microscopic structural heterogeneities in these metallic glasses. Based on stochastically statistic defect model, we found that the defect density decreases with increasing annealing temperature and annealing time and is exponentially related to the fracture energy. A ductile-versus-brittle behavior (DBB) model based on the structural heterogeneity is developed to identify the physical origins of the embrittlement behavior through the interactions between these defects and crack tip.

  9. On the correlation between microscopic structural heterogeneity and embrittlement behavior in metallic glasses

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

    Li, Weidong; Gao, Yanfei; Bei, Hongbin

    2015-10-05

    To establish a relationship between microstructure and mechanical properties, we systematically annealed a Zr-based bulk metallic glass (BMG) at 100 ~ 300°C and measured their mechanical and thermal properties. The as-cast BMG exhibits some ductility, while the increase of annealing temperature and time leads to the transition to a brittle behavior that can reach nearly-zero fracture energy. The differential scanning calorimetry did not find any significant changes in crystallization temperature and enthalpy, indicating that the materials still remained fully amorphous. Elastic constants measured by ultrasonic technique vary only slightly with respect to annealing temperature and time, which does obey themore » empirical relationship between Poisson’s ratio and fracture behavior. Nanoindentation pop-in tests were conducted, from which the pop-in strength mapping provides a “mechanical probe” of the microscopic structural heterogeneities in these metallic glasses. Based on stochastically statistic defect model, we found that the defect density decreases with increasing annealing temperature and annealing time and is exponentially related to the fracture energy. A ductile-versus-brittle behavior (DBB) model based on the structural heterogeneity is developed to identify the physical origins of the embrittlement behavior through the interactions between these defects and crack tip.« less

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

    DOE Patents [OSTI]

    Kaiser, Timothy D.; Daniel, Sabah S.; Dykes, Charles D.

    1989-03-21

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

  11. Ductile-to-brittle transition in spallation of metallic glasses

    SciTech Connect (OSTI)

    Huang, X.; Ling, Z.; Dai, L. H.

    2014-10-14

    In this paper, the spallation behavior of a binary metallic glass Cu{sub 50}Zr{sub 50} is investigated with molecular dynamics simulations. With increasing the impact velocity, micro-voids induced by tensile pulses become smaller and more concentrated. The phenomenon suggests a ductile-to-brittle transition during the spallation process. Further investigation indicates that the transition is controlled by the interaction between void nucleation and growth, which can be regarded as a competition between tension transformation zones (TTZs) and shear transformation zones (STZs) at atomic scale. As impact velocities become higher, the stress amplitude and temperature rise in the spall region increase and micro-structures of the material become more unstable. Therefore, TTZs are prone to activation in metallic glasses, leading to a brittle behavior during the spallation process.

  12. Application of Thread-Forming Fasteners in Net-Shaped Cast Holes in Lightweight Metal Alloys

    SciTech Connect (OSTI)

    Paxton, Dean M.; Dudder, Gregory J.; Charron, William A.; Cleaver, Todd H.

    2006-03-12

    The application of thread-forming fasteners (TFFs) in net-shaped die-cast holes of lightweight metal alloys is being explored by the United States Automotive Materials Partnership (USAMP) through work at the Pacific Northwest National Laboratory (PNNL). These fasteners are being applied in drilled hole applications for general assembly which have reduced costs, reduced investment, and improved warranty while delivering better joint properties. Successful development of this idea in light-weight alloy die-cast products will expand the use of lightweight materials due to the proven benefits already achieved in existing applications. A portion of this effort has included a parametric study of the relationship between joint strength and as-cast hole geometry in aluminum alloy A380 test specimens.

  13. Medium-range structure and glass forming ability in Zr–Cu–Al bulk metallic glasses

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

    Zhang, Pei; Maldonis, Jason J.; Besser, M. F.; Kramer, M. J.; Voyles, Paul M.

    2016-03-05

    Fluctuation electron microscopy experiments combined with hybrid reverse Monte Carlo modeling show a correlation between medium-range structure at the nanometer scale and glass forming ability in two Zr–Cu–Al bulk metallic glass (BMG) alloys. Both Zr50Cu35Al15 and Zr50Cu45Al5 exhibit two nanoscale structure types, one icosahedral and the other more crystal-like. In Zr50Cu35Al15, the poorer glass former, the crystal-like structure is more stable under annealing below the glass transition temperature, Tg, than in Zr50Cu45Al5. Variable resolution fluctuation microscopy of the MRO clusters show that in Zr50Cu35Al15 on sub-Tg annealing, the crystal-like clusters shrink even as they grow more ordered, while icosahedral-like clustersmore » grow. Furthermore, the results suggest that achieving better glass forming ability in this alloy system may depend more on destabilizing crystal-like structures than enhancing non-crystalline structures.« less

  14. Metallic glass alloys of Zr, Ti, Cu and Ni

    DOE Patents [OSTI]

    Lin, Xianghong; Peker, Atakan; Johnson, William L.

    1997-01-01

    At least quaternary alloys form metallic glass upon cooling below the glass transition temperature at a rate less than 10.sup.3 K/s. Such alloys comprise titanium from 19 to 41 atomic percent, an early transition metal (ETM) from 4 to 21 atomic percent and copper plus a late transition metal (LTM) from 49 to 64 atomic percent. The ETM comprises zirconium and/or hafnium. The LTM comprises cobalt and/or nickel. The composition is further constrained such that the product of the copper plus LTM times the atomic proportion of LTM relative to the copper is from 2 to 14. The atomic percentage of ETM is less than 10 when the atomic percentage of titanium is as high as 41, and may be as large as 21 when the atomic percentage of titanium is as low as 24. Furthermore, when the total of copper and LTM are low, the amount of LTM present must be further limited. Another group of glass forming alloys has the formula (ETM.sub.1-x Ti.sub.x).sub.a Cu.sub.b (Ni.sub.1-y Co.sub.y).sub.c wherein x is from 0.1 to 0.3, y.cndot.c is from 0 to 18, a is from 47 to 67, b is from 8 to 42, and c is from 4 to 37. This definition of the alloys has additional constraints on the range of copper content, b.

  15. 'Fore!' heads up, wide use of more flexible metallic glass coming your

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

    way Flexible metallic glass coming your way 'Fore!' heads up, wide use of more flexible metallic glass coming your way Scientists are working toward even stronger and more elastic glass types which would fail in a ductile fashion instead of shattering. March 3, 2014 A piece of metallic glass that has been bent around onto itself with a 1mm radius and glued into place. It would spring back to a flat piece if the glue were removed. A piece of metallic glass that has been bent around onto

  16. Apparatus for injection casting metallic nuclear energy fuel rods

    DOE Patents [OSTI]

    Seidel, Bobby R.; Tracy, Donald B.; Griffiths, Vernon

    1991-01-01

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

  17. Glass-ceramic hermetic seals to high thermal expansion metals

    DOE Patents [OSTI]

    Kramer, D.P.; Massey, R.T.

    1987-04-28

    A process for forming glass-ceramic materials from an alkaline silica-lithia glass composition comprising 60-72 mole-% SiO/sub 2/, 18-27 mole-% Li/sub 2/O, 0-5 mole-% Al/sub 2/O/sub 3/, 0-6 mole-% K/sub 2/O, 0-3 mole-% B/sub 2/O/sub 3/, and 0.5-2.5 mole-% P/sub 2/O/sub 5/, which comprises heating said glass composition at a first temperature within the 950-1050/degree/C range for 5-60 minutes, and then at a devitrification temperature within the 700-900/degree/C range for about 5-300 minutes to obtain a glass-ceramic having a thermal expansion coefficient of up to 210 x 10/sup /minus/7///degree/C. These ceramics form strong, hermetic seals with high expansion metals such as stainless steel alloys. An intermediate nucleation heating step conducted at a temperature within the range of 675-750/degree/C for 10-120 minutes may be employed between the first stage and the devitrification stage. 1 fig., 2 tabs.

  18. Atomic and electronic structure of Ni-Nb metallic glasses

    SciTech Connect (OSTI)

    Yuan, C. C.; Yang, Y.-F. Xi, X. K.

    2013-12-07

    Solid state {sup 93}Nb nuclear magnetic resonance spectroscopy has been employed to investigate the atomic and electronic structures in Ni-Nb based metallic glass (MG) model system. {sup 93}Nb nuclear magnetic resonance (NMR) isotropic metallic shift of Ni{sub 60}Nb{sub 35}Sn{sub 5} has been found to be ∼100 ppm lower than that of Ni{sub 60}Nb{sub 35}Zr{sub 5} MG, which is correlated with their intrinsic fracture toughness. The evolution of {sup 93}Nb NMR isotropic metallic shifts upon alloying is clearly an electronic origin, as revealed by both local hyperfine fields analysis and first-principle computations. This preliminary result indicates that, in addition to geometrical considerations, atomic form factors should be taken into a description of atomic structures for better understanding the mechanical behaviors of MGs.

  19. Metallic glass alloys of Zr, Ti, Cu and Ni

    DOE Patents [OSTI]

    Lin, X.; Peker, A.; Johnson, W.L.

    1997-04-08

    At least quaternary alloys form metallic glass upon cooling below the glass transition temperature at a rate less than 10{sup 3} K/s. Such alloys comprise titanium from 19 to 41 atomic percent, an early transition metal (ETM) from 4 to 21 atomic percent and copper plus a late transition metal (LTM) from 49 to 64 atomic percent. The ETM comprises zirconium and/or hafnium. The LTM comprises cobalt and/or nickel. The composition is further constrained such that the product of the copper plus LTM times the atomic proportion of LTM relative to the copper is from 2 to 14. The atomic percentage of ETM is less than 10 when the atomic percentage of titanium is as high as 41, and may be as large as 21 when the atomic percentage of titanium is as low as 24. Furthermore, when the total of copper and LTM are low, the amount of LTM present must be further limited. Another group of glass forming alloys has the formula (ETM{sub 1{minus}x}Ti{sub x}){sub a} Cu{sub b} (Ni{sub 1{minus}y}Co{sub y}){sub c} wherein x is from 0.1 to 0.3, y{center_dot}c is from 0 to 18, a is from 47 to 67, b is from 8 to 42, and c is from 4 to 37. This definition of the alloys has additional constraints on the range of copper content, b. 2 figs.

  20. Methods of making metallic glass foil laminate composites

    DOE Patents [OSTI]

    Vianco, Paul T.; Fisher, Robert W.; Hosking, Floyd M.; Zanner, Frank J.

    1996-01-01

    A process for the fabrication of a rapidly solidified foil laminate composite. An amorphous metallic glass foil is flux treated and coated with solder. Before solidification of the solder the foil is collected on a take-up spool which forms the composite into a solid annular configuration. The resulting composite exhibits high strength, resiliency and favorable magnetic and electrical properties associated with amorphous materials. The composite also exhibits bonding strength between the foil layers which significantly exceeds the bulk strength of the solder alone.

  1. Methods of making metallic glass foil laminate composites

    DOE Patents [OSTI]

    Vianco, P.T.; Fisher, R.W.; Hosking, F.M.; Zanner, F.J.

    1996-08-20

    A process for the fabrication of a rapidly solidified foil laminate composite. An amorphous metallic glass foil is flux treated and coated with solder. Before solidification of the solder the foil is collected on a take-up spool which forms the composite into a solid annular configuration. The resulting composite exhibits high strength, resiliency and favorable magnetic and electrical properties associated with amorphous materials. The composite also exhibits bonding strength between the foil layers which significantly exceeds the bulk strength of the solder alone. 6 figs.

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

    SciTech Connect (OSTI)

    Sabau, Adrian S [ORNL

    2006-01-01

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

  3. Technology development for thin strip metal casting, Phase 2: Final technical report. [Melt spinning or planar flow casting

    SciTech Connect (OSTI)

    Williams, R.S.

    1988-03-07

    The Phase II program has been conducted by a team of engineers from Westinghouse Electric Corporation and Armco, Inc., with the objective of providing a suitably sized experimental planar flow casting machine, and using it to perform casting trials to address the above technical uncertainties for cast thicknesses and speeds representative of industrial production, and with sufficient duration to diminish thermal transient effects. A nominally 7 ft. diameter water-cooled copper wheel planar flow casting system has been designed, fabricated and installed in a dedicated 15,000 sq. ft. foundry facility are Armco Inc., Middletown, Ohio. This system is capable of casting 3 in. wide strip and operating at surface speeds up to 25 ft/sec. Additionally, the facility also contains a 16 in. diameter water-cooled wheel with interchangeable casting substrates of different materials. This small wheel facility has been adapted to utilize the melt overflow process for casting of 3 in. wide strip. These casting facilities are supported by a 500 lb. induction melting furnace and necessary liquid steel handling equipment. Adequate techniques have been developed for transportation and filtering of liquid steel without undue temperature loss. Good control of the planar flow casting process was not achieved during this program, however given such control and the adoption of clean steel practices, the inference is that the process will be capable of producing strip which is readily cold-rollable in the as-cast condition. After cold rolling and annealing, such material should have useful mechanical properties. 8 refs., 112 figs., 10 tabs.

  4. Metallic glass could make your next cell phone harder to break

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

    (such as metallic glass) are for recreational purposes. Imhoff pointed out that sports are often early adopters of new materials technology because even the slightest...

  5. Inherent structure length in metallic glasses: Simplicity behind complexity

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

    Wu, Yuan; Wang, Hui; Cheng, Yongqiang; Liu, Xiongjun; Hui, Xidong; Nieh, Taigang; Wang, Yandong; Lu, Zhaoping

    2015-08-06

    One of the central themes in materials science is the structure-property relationship. In conventional crystalline metals, their mechanical behaviour is often dictated by well-defined structural defects such as dislocations, impurities, and twins. However, the structure-property relationship in amorphous alloys is far from being understood, due to great difficulties in characterizing and describing the disordered atomic-level structure. Here, we report a universal, yet simple, correlation between the macroscopic mechanical properties (i.e., yield strength and shear modulus) and a unique characteristic structural length in metallic glasses (MGs). Lastly, our analysis indicates that this characteristic length can incorporate effects of both the inter-atomicmore » distance and valence electron density in MGs, and result in the observed universal correlation. The current findings shed lights on the basic understanding of mechanical properties of MGs from their disordered atomic structures.« less

  6. Inherent structure length in metallic glasses: Simplicity behind complexity

    SciTech Connect (OSTI)

    Wu, Yuan; Wang, Hui; Cheng, Yongqiang; Liu, Xiongjun; Hui, Xidong; Nieh, Taigang; Wang, Yandong; Lu, Zhaoping

    2015-08-06

    One of the central themes in materials science is the structure-property relationship. In conventional crystalline metals, their mechanical behaviour is often dictated by well-defined structural defects such as dislocations, impurities, and twins. However, the structure-property relationship in amorphous alloys is far from being understood, due to great difficulties in characterizing and describing the disordered atomic-level structure. Here, we report a universal, yet simple, correlation between the macroscopic mechanical properties (i.e., yield strength and shear modulus) and a unique characteristic structural length in metallic glasses (MGs). Lastly, our analysis indicates that this characteristic length can incorporate effects of both the inter-atomic distance and valence electron density in MGs, and result in the observed universal correlation. The current findings shed lights on the basic understanding of mechanical properties of MGs from their disordered atomic structures.

  7. Devitrification kinetics and phase selection mechanisms in Cu-Zr metallic glasses

    SciTech Connect (OSTI)

    Kalay, Ilkay

    2010-12-15

    Metallic glasses have been a promising class of materials since their discovery in the 1960s. Indeed, remarkable chemical, mechanical and physical properties have attracted considerable attention, and several excellent reviews are available. Moreover, the special group of glass forming alloys known as the bulk metallic glasses (BMG) become amorphous solids even at relatively low cooling rates, allowing them to be cast in large cross sections, opening the scope of potential applications to include bulk forms and net shape structural applications. Recent studies have been reported for new bulk metallic glasses produced with lower cooling rates, from 0.1 to several hundred K/s. Some of the application products of BMGs include sporting goods, high performance springs and medical devices. Several rapid solidification techniques, including melt-spinning, atomization and surface melting have been developed to produce amorphous alloys. The aim of all these methods is to solidify the liquid phase rapidly enough to suppress the nucleation and growth of crystalline phases. Furthermore, the production of amorphous/crystalline composite (ACC) materials by partial crystallization of amorphous precursor has recently given rise to materials that provide better mechanical and magnetic properties than the monolithic amorphous or crystalline alloys. In addition, these advances illustrate the broad untapped potential of using the glassy state as an intermediate stage in the processing of new materials and nanostructures. These advances underlie the necessity of investigations on prediction and control of phase stability and microstructural dynamics during both solidification and devitrification processes. This research presented in this dissertation is mainly focused on Cu-Zr and Cu-Zr-Al alloy systems. The Cu-Zr binary system has high glass forming ability in a wide compositional range (35-70 at.% Cu). Thereby, Cu-Zr based alloys have attracted much attention according to fundamental

  8. Process for direct conversion of reactive metals to glass (Patent...

    Office of Scientific and Technical Information (OSTI)

    is contacted with silica powder introduced in an air stream to form in one step a glass. ... contacted; silica; powder; introduced; air; stream; form; step; glass; cyclone; ...

  9. In-situ ductile metal/bulk metallic glass matrix composites formed by chemical partitioning

    DOE Patents [OSTI]

    Kim, Choong Paul (Northridge, CA); Hays, Charles C. (Pasadena, CA); Johnson, William L. (Pasadena, CA)

    2007-07-17

    A composite metal object comprises ductile crystalline metal particles in an amorphous metal matrix. An alloy is heated above its liquidus temperature. Upon cooling from the high temperature melt, the alloy chemically partitions, forming dendrites in the melt. Upon cooling the remaining liquid below the glass transition temperature it freezes to the amorphous state, producing a two-phase microstructure containing crystalline particles in an amorphous metal matrix. The ductile metal particles have a size in the range of from 0.1 to 15 micrometers and spacing in the range of from 0.1 to 20 micrometers. Preferably, the particle size is in the range of from 0.5 to 8 micrometers and spacing is in the range of from 1 to 10 micrometers. The volume proportion of particles is in the range of from 5 to 50% and preferably 15 to 35%. Differential cooling can produce oriented dendrites of ductile metal phase in an amorphous matrix. Examples are given in the Zr--Ti--Cu--Ni--Be alloy bulk glass forming system with added niobium.

  10. In-situ ductile metal/bulk metallic glass matrix composites formed by chemical partitioning

    DOE Patents [OSTI]

    Kim, Choong Paul; Hays, Charles C.; Johnson, William L.

    2004-03-23

    A composite metal object comprises ductile crystalline metal particles in an amorphous metal matrix. An alloy is heated above its liquidus temperature. Upon cooling from the high temperature melt, the alloy chemically partitions, forming dendrites in the melt. Upon cooling the remaining liquid below the glass transition temperature it freezes to the amorphous state, producing a two-phase microstructure containing crystalline particles in an amorphous metal matrix. The ductile metal particles have a size in the range of from 0.1 to 15 micrometers and spacing in the range of from 0.1 to 20 micrometers. Preferably, the particle size is in the range of from 0.5 to 8 micrometers and spacing is in the range of from 1 to 10 micrometers. The volume proportion of particles is in the range of from 5 to 50% and preferably 15 to 35%. Differential cooling can produce oriented dendrites of ductile metal phase in an amorphous matrix. Examples are given in the Zr--Ti--Cu--Ni--Be alloy bulk glass forming system with added niobium.

  11. High-entropy bulk metallic glasses as promising magnetic refrigerants

    SciTech Connect (OSTI)

    Huo, Juntao; Huo, Lishan; Li, Jiawei; Men, He; Wang, Xinmin; Chang, Chuntao E-mail: jqwang@nimte.ac.cn; Wang, Jun-Qiang E-mail: jqwang@nimte.ac.cn; Li, Run-Wei; Inoue, Akihisa

    2015-02-21

    In this paper, the Ho{sub 20}Er{sub 20}Co{sub 20}Al{sub 20}RE{sub 20} (RE = Gd, Dy, and Tm) high-entropy bulk metallic glasses (HE-BMGs) with good magnetocaloric properties are fabricated successfully. The HE-BMGs exhibit a second-order magnetic phase transition. The peak of magnetic entropy change (ΔS{sub M}{sup pk}) and refrigerant capacity (RC) reaches 15.0 J kg{sup −1} K{sup −1} and 627 J kg{sup −1} at 5 T, respectively, which is larger than most rare earth based BMGs. The heterogeneous nature of glasses also contributes to the large ΔS{sub M}{sup pk} and RC. In addition, the magnetic ordering temperature, ΔS{sub M}{sup pk} and RC can be widely tuned by alloying different rare earth elements. These results suggest that the HE-BMGs are promising magnetic refrigerant at low temperatures.

  12. Atomic picture of elastic deformation in a metallic glass

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

    Wang, X. D.; Aryal, S.; Zhong, C.; Ching, W. Y.; Sheng, H. W.; Zhang, H.; Zhang, D. X.; Cao, Q. P.; Jiang, J. Z.

    2015-03-17

    The tensile behavior of a Ni₆₀Nb₄₀ metallic glass (MG) has been studied by using ab initio density functional theory (DFT) calculation with a large cell containing 1024 atoms (614 Ni and 410 Nb). We provide insight into how a super elastic limit can be achieved in a MG. Spatially inhomogeneous responses of single atoms and also major polyhedra are found to change greatly with increasing external stress when the strain is over 2%, causing the intrinsically viscoelastic behavior. We uncover the origin of the observed super elastic strain limit under tension (including linear and viscoelastic strains) in small-sized MG samples,more » mainly caused by inhomogeneous distribution of excess volumes in the form of newly formed subatomic cavities.« less

  13. Crossover from localized to cascade relaxations in metallic glasses

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

    Fan, Yue; Iwashita, Takuya; Egami, Takeshi

    2015-07-21

    Thermally activated deformation is investigated in two metallic glass systems with different cooling histories. By probing the atomic displacements and stress changes on the potential energy landscape, two deformation modes, a localized process and cascade process, have observed. The localized deformation involves fewer than 30 atoms and appears in both systems, and its size is invariant with cooling history. However, the cascade deformation is more frequently observed in the fast quenched system than in the slowly quenched system. As a result, the origin of the cascade process in the fast quenched system is attributed to the higher density of localmore » minima on the underlying potential energy landscape.« less

  14. Atomic picture of elastic deformation in a metallic glass

    SciTech Connect (OSTI)

    Wang, X. D.; Aryal, S.; Zhong, C.; Ching, W. Y.; Sheng, H. W.; Zhang, H.; Zhang, D. X.; Cao, Q. P.; Jiang, J. Z.

    2015-03-17

    The tensile behavior of a Ni??Nb?? metallic glass (MG) has been studied by using ab initio density functional theory (DFT) calculation with a large cell containing 1024 atoms (614 Ni and 410 Nb). We provide insight into how a super elastic limit can be achieved in a MG. Spatially inhomogeneous responses of single atoms and also major polyhedra are found to change greatly with increasing external stress when the strain is over 2%, causing the intrinsically viscoelastic behavior. We uncover the origin of the observed super elastic strain limit under tension (including linear and viscoelastic strains) in small-sized MG samples, mainly caused by inhomogeneous distribution of excess volumes in the form of newly formed subatomic cavities.

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

    SciTech Connect (OSTI)

    Jablonski, Paul D.; Turner, Paul C.

    2005-09-01

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

  16. Method and apparatus for performing in-situ vacuum-assisted metal to glass sealing

    DOE Patents [OSTI]

    Kramer, D.P.; Massey, R.T.

    1985-07-18

    A method and apparatus for assembling and fusing glass to metal in a glass-metal electrical component is disclosed. The component includes a metallic shell formed with upper and lower cylindrical recesses connected together by longitudinal passages, a pair of metal rings and plural metal pins assembled to define electrical feed-throughs. The component parts are assembled on a fixture having a sleeve-like projection and a central mounting projection establishing concentric nesting surfaces to which the metal rings are slip-fitted in concentric alignment with each other spaced from sidewalls of the lower recess. The pins are in electrical contact with the metal rings. A glass pre-form is seated within the upper recess. The assembled structure is heated to a temperature sufficient to melt the glass pre-form which flows under gravity through the passages into the lower recess to provide an insulative seal between the metal parts. The gravity flow of glass is assisted by applying vacuum to the lower recess, ensuring that all spaces between the metal parts are filled with sealing glass without formation of bubbles.

  17. Method and apparatus for performing in-situ vacuum-assisted metal to glass sealing

    DOE Patents [OSTI]

    Kramer, Daniel P.; Massey, Richard T.

    1986-01-01

    A method and apparatus for assembling and fusing glass to metal in a glass-metal electrical component is disclosed. The component includes a metallic shell formed with upper and lower cylindrical recesses connected together by longitudinal passages, a pair of metal rings and plural metal pins assembled to define electrical feed-throughs. The component parts are assembled on a fixture having a sleeve-like projection and a central mounting projection establishing concentric nesting surfaces to which the metal rings are slip-fitted in concentric alignment with each other spaced from sidewalls of the lower recess. The pins are in electrical contact with the metal rings. A glass pre-form is seated within the upper recess. The assembled structure is heated to a temperature sufficient to melt the glass pre-form which flows under gravity through the passages into the lower recess to provide an insulative seal between the metal parts. The gravity flow of glass is assisted by applying vacuum to the lower recess, ensuring that all spaces between the metal parts are filled with sealing glass without formation of bubbles.

  18. Fabrication and Characterization of Graded Impedance Gas Gun Impactors from Tape Cast Metal Powders

    SciTech Connect (OSTI)

    Martin, L P; Nguyen, J H

    2005-11-21

    Fabrication of compositionally graded structures for use as light-gas gun impactors has been demonstrated using a tape casting technique. Mixtures of metal powders in the Mg-Cu system were cast into a series of tapes with uniform compositions ranging from 100% Mg to 100% Cu. The individual compositions were fabricated into monolithic pellets for characterization by laminating multiple layers together, thermally removing the organics, and hot-pressing to near-full density. The pellets were characterized by optical and scanning electron microscopy, X-ray diffraction, and measurement of density and sound wave velocity. The density and acoustic impedance were observed to vary monotonically (and nearly linearly) with composition. Graded structures were fabricated by stacking layers of different compositions in a sequence calculated to yield a desired acoustic impedance profile. The measured physical properties of the graded structures compare favorably with those predicted from the monolithic-pellet characteristics. Fabrication of graded impactors by this technique is of significant interest for providing improved control of the pressure profile in gas gun experiments.

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

    SciTech Connect (OSTI)

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

    2013-10-01

    Thermal cycling and melt reaction studies of ceramic coatings plasma-sprayed on Nb substrates were carried out to evaluate the performance of barrier coatings for metallic fuel casting applications. Thermal cycling tests of the ceramic plasma-sprayed coatings to 1450 degrees C showed that HfN, TiC, ZrC, and Y2O3 coating had good cycling characteristics with few interconnected cracks even after 20 cycles. Interaction studies by 1550 degrees C melt dipping tests of the plasma-sprayed coatings also indicated that HfN and Y2O3 do not form significant reaction layer between U20 wt.% Zr melt and the coating layer. Plasma-sprayed Y2O3 coating exhibited the most promising characteristics among HfN, TiC, ZrC, and Y2O3 coating.

  20. Tuned critical avalanche scaling in bulk metallic glasses

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

    Antonaglia, James; Xie, Xie; Schwarz, Gregory; Wraith, Matthew; Qiao, Junwei; Zhang, Yong; Liaw, Peter K.; Uhl, Jonathan T.; Dahmen, Karin A.

    2014-03-17

    In this study, ingots of the bulk metallic glass (BMG), Zr64.13Cu15.75Ni10.12Al10 in atomic percent (at. %), are compressed at slow strain rates. The deformation behavior is characterized by discrete, jerky stress-drop bursts (serrations). Here we present a quantitative theory for the serration behavior of BMGs, which is a critical issue for the understanding of the deformation characteristics of BMGs. The mean-field interaction model predicts the scaling behavior of the distribution, D(S), of avalanche sizes, S, in the experiments. D(S) follows a power law multiplied by an exponentially-decaying scaling function. The size of the largest observed avalanche depends on experimental tuning-parameters,more » such as either imposed strain rate or stress. Similar to crystalline materials, the plasticity of BMGs reflects tuned criticality showing remarkable quantitative agreement with the slip statistics of slowly-compressed nanocrystals. The results imply that material-evaluation methods based on slip statistics apply to both crystalline and BMG materials.« less

  1. Alternative granular media for the metal casting industry. Final report, September 30, 1994

    SciTech Connect (OSTI)

    Guichelaar, P.J.; Ramrattan, S.N.; Tieder, R.E.

    1995-09-01

    Silica sand for foundry use is inexpensive to purchase, readily transported and widely available. As a result, it is universally used. However, three factors are becoming increasingly significant as more environmental regulations are promulgated. First, the disposal of waste foundry sand has become an excessively burdensome cost. Second, the phase changes which occur in the silica structure on heating and cooling cause thermal breakdown of the sand into smaller unusable fractions. Third, silica is a relatively weak mineral. Alternatives to silica sand which can withstand the rigors of repetitive reuse must be seriously evaluated as a way to control production costs of the domestic metal casting industry. Chromite sands, olivine sands and carbon sands have each been successfully used to solve operating problems and thus have developed their specific niches in the foundry materials inventory. However, there are several other materials that are candidates for replacing silica sand, such as fused alumina, sintered bauxite and sintered oil well proppants. These media, and others that are generically similar, are manufactured for specific purposes. Compositions and shapes could be readily tailored for used in a metal casting environment of total recycling and materials conservation. This study examines materials that are readily available as alternatives to silica sand from a functionality perspective and a cost perspective. Some of the alternative materials are natural and others are synthetic and thus referring to them as ``sands`` has the potential to cause confusion; the generic term ``granular medium`` is used in this study to mean any material that could functionally substitute for silica sand in the foundry process.

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

    SciTech Connect (OSTI)

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

    1995-08-01

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

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

    DOE Patents [OSTI]

    Kinosz, Michael J.; Meyer, Thomas N.

    2003-02-11

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

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

    SciTech Connect (OSTI)

    Crapps, Justin M.; Galloway, Jack D.; Decroix, David S.; Korzekwa, David A.; Aikin, Robert M. Jr.; Unal, Cetin; Fielding, R.; Kennedy, R

    2012-06-29

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

  5. Mechanical Properties and Microstructure of Plasma Sprayed Ni-Based Metallic Glass Coating

    SciTech Connect (OSTI)

    Kobayashi, Akira; Kuroda, Toshio; Kimura, Hisamichi; Inoue, Akihisa

    2010-10-13

    Various developmental research works on the metallic glass have been conducted in order to broaden its application field. Thermal spraying method is one of the potential techniques to enhance the excellent properties such as high toughness and corrosion resistance of the metallic glass material. The gas tunnel type plasma spraying is useful to obtain high quality ceramic coatings such as Al{sub 2}O{sub 3} and ZrO{sub 2} coatings. In this study, the Ni-based metallic glass coatings were produced by the gas tunnel type plasma spraying under various experimental conditions, and their microstructure and mechanical properties were investigated. At the plasma current of 200-300 A, the Ni-based metallic glass coatings of more than 200 {mu}m in thickness were formed densely with Vickers hardness of about Hv = 600.

  6. Metal and Glass Manufacturers Reduce Costs by Increasing Energy...

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

    Process heating plays a key role in producing steel, aluminum, and glass and in ... More Documents & Publications Commonwealth Aluminum: Manufacturer Conducts Plant-Wide ...

  7. Measurement of local internal friction in metallic glasses

    SciTech Connect (OSTI)

    Wagner, H.; Bchsenschtz-Gbeler, M.; Luo, Y.; Samwer, K.; Kumar, A.; Arnold, W.

    2014-04-07

    Atomic force acoustic microscopy (AFAM), an advanced scanning probe microscopy technique, has been used to measure local elastic properties with a spatial resolution given by the tip-sample contact radius. AFAM is based on inducing out-of-plane vibrations in the specimen. The vibrations are sensed by the AFM cantilever from by the photodiode signal when its tip is in contact with the material under test. To measure local damping, the inverse quality factor Q{sup ?1} of the resonance curve is usually evaluated. Here, from the contact-resonance spectra obtained, we determine the real and imaginary part of the contact stiffness k* and from these two quantities the local damping factor Q{sub loc}{sup ?1} is obtained which is proportional to the imaginary part ? of the contact stiffness. The evaluation of the data is based on the cantilever's mass distribution with damped flexural modes and not on an effective point-mass approximation for the cantilevers motion. The given equation is simple to use and has been employed to study the local Q{sub loc}{sup ?1} of amorphous PdCuSi metallic glass and its crystalline counterpart as a function of position of the AFM tip on the surface. The width of the distribution changes dramatically from the amorphous to the crystalline state as expected from the consequences of the potential-energy landscape picture. The center value of the distribution curve for Q{sub loc}{sup ?1} coincides very well with published data, based on global ultrasonic or internal friction measurements. This is compared to Q{sub loc}{sup ?1} measured in crystalline SrTiO{sub 3}, which exhibits a narrow distribution, as expected.

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

    SciTech Connect (OSTI)

    Robert D. Pehlke; John T. Berry

    2005-12-16

    Accurate modeling of the metal casting process prior to creating a mold design demands reliable knowledge of the interfacial heat transfer coefficient at the mold metal interface as a function of both time and location. The phenomena concerned with the gap forming between the mold and the solidifying metal are complex but need to be understood before any modeling is attempted. The presence of mold coatings further complicates the situation. A commercial casting was chosen and studied in a gravity permanent mold casting process. The metal/mold interfacial heat transfer coefficient (IHTC) was the focus of the research. A simple, direct method has been used to evaluate the IHTC. Both the simulation and experiments have shown that a reasonably good estimate of the heat transfer coefficient could be made in the case studied. It has been found that there is a good agreement between experiments and simulations in the temperature profiles during the solidification process, given that the primary mechanism of heat transfer across the gap in permanent mold casting of light alloys is by conduction across the gap. The procedure utilized to determine the interfacial heat transfer coefficient can be applied to other casting processes. A recently completed project involving The University of Michigan and Mississippi State University, together with several industrial partners, which was supported by the USDOE through the Cast Metals Coalition, examined a number of cases of thermal contact. In an investigation which gave special consideration to the techniques of measurement, several mold coatings were employed and results presented as a function of time. Realistic conditions of coating thickness and type together with an appropriate combination of mold preheat and metal pouring temperature were strictly maintained throughout the investigation. Temperature sensors, in particular thermocouples, play an important part in validating the predictions of solidification models. Cooling

  9. Glass

    Broader source: Energy.gov [DOE]

    Glass production requires considerable energy to sustain the very high temperatures needed to melt the glass batch. The U.S. glass industry has worked cooperatively with AMO to develop a range of resources for improving energy efficiency and reducing emissions.

  10. Lowering critical cooling rate for forming bulk metallic glass

    SciTech Connect (OSTI)

    Shen, T.D.; Schwarz, R.B. [MS G755, MST-8, Materials Science and Technology Division, Los Alamos National Laboratory, Los Alamos, New Mexico 87545 (United States)

    2006-02-27

    Small volumes of Pd{sub 44}Ni{sub 10}Cu{sub 26}P{sub 20} and Pd{sub 43.2}Ni{sub 8.8}Cu{sub 28}P{sub 20} were encapsulated in B{sub 2}O{sub 3} and thermally cycled between T{sub g}-60 deg. C and T{sub l}+60 deg. C, where T{sub g} and T{sub l} denote the alloys' glass transition and liquidus temperatures. After this thermal treatment, the critical cooling rates (CCRs) for glass formation can be lowered by an order of magnitude, resulting in a critical cooling rate significantly lower than that reported for any other glass forming alloy melt. These experiments demonstrate that the CCR is not constant but strongly dependent on the degree of heterogeneous nucleation.

  11. Proposed Testing to Assess the Accuracy of Glass-To-Metal Seal Stress Analyses.

    SciTech Connect (OSTI)

    Chambers, Robert S.; Emery, John M; Tandon, Rajan; Antoun, Bonnie R.; Stavig, Mark E.; Newton, Clay S.; Gibson, Cory S; Bencoe, Denise N.

    2014-09-01

    The material characterization tests conducted on 304L VAR stainless steel and Schott 8061 glass have provided higher fidelity data for calibration of material models used in Glass - T o - Metal (GTM) seal analyses. Specifically, a Thermo - Multi - Linear Elastic Plastic ( thermo - MLEP) material model has be en defined for S S304L and the Simplified Potential Energy Clock nonlinear visc oelastic model has been calibrated for the S8061 glass. To assess the accuracy of finite element stress analyses of GTM seals, a suite of tests are proposed to provide data for comparison to mo del predictions.

  12. Structural evolution in Ti-Cu-Ni metallic glasses during heating

    SciTech Connect (OSTI)

    Gargarella, P.; Pauly, S.; Stoica, M.; Khn, U.; Vaughan, G.; Afonso, C. R. M.; Eckert, J.

    2015-01-01

    The structural evolution of Ti{sub 50}Cu{sub 43}Ni{sub 7} and Ti{sub 55}Cu{sub 35}Ni{sub 10} metallic glasses during heating was investigated by in-situ synchrotron X-ray diffraction. The width of the most intense diffraction maximum of the glassy phase decreases slightly during relaxation below the glass transition temperature. Significant structural changes only occur above the glass transition manifesting in a change in the respective peak positions. At even higher temperatures, nanocrystals of the shape memory B2-Ti(Cu,Ni) phase precipitate, and their small size hampers the occurrence of a martensitic transformation.

  13. Auger CVV spectra as a probe of the electronic structure of metallic glasses

    SciTech Connect (OSTI)

    Bevolo, A.J.; Severin, C.S.; Chen, C.W.

    1982-03-01

    Additional data on the Auger KVV spectra of Be and B in the Fe/sub 82/B/sub 18-x/Be/sub x/ ferromagnetic metallic glass system are presented. A weak but sharp peak in the B KVV spectra of the ternary alloys is identified with a Fe--B bonding state that is also present in the binary Fe--B metallic glass system. In addition to the previously reported 14-eV shift in the Be KVV energy for x< or =4 a narrowing of the linewidth of this transition from 8 to 5 eV is reported for the same composition range. Several models are considered to explain the unusual Be KVV Auger results for the ternary Fe--B--Be metallic glass system.

  14. Linking structure to fragility in bulk metallic glass-forming liquids

    SciTech Connect (OSTI)

    Wei, Shuai E-mail: m.stolpe@mx.uni-saarland.de; Stolpe, Moritz E-mail: m.stolpe@mx.uni-saarland.de; Gross, Oliver; Gallino, Isabella; Hembree, William; Busch, Ralf; Evenson, Zach; Bednarcik, Jozef; Kruzic, Jamie J.

    2015-05-04

    Using in-situ synchrotron X-ray scattering, we show that the structural evolution of various bulk metallic glass-forming liquids can be quantitatively connected to their viscosity behavior in the supercooled liquid near T{sub g}. The structural signature of fragility is identified as the temperature dependence of local dilatation on distinct key atomic length scales. A more fragile behavior results from a more pronounced thermally induced dilatation of the structure on a length scale of about 3 to 4 atomic diameters, coupled with shallower temperature dependence of structural changes in the nearest neighbor environment. These findings shed light on the structural origin of viscous slowdown during undercooling of bulk metallic glass-forming liquids and demonstrate the promise of predicting the properties of bulk metallic glasses from the atomic scale structure.

  15. Propensity of bond exchange as a window into the mechanical properties of metallic glasses

    SciTech Connect (OSTI)

    Jiao, W.; Wang, X. L. Lan, S.; Pan, S. P.; Lu, Z. P.

    2015-02-09

    We investigated the mechanical properties of Zr-Cu-Al bulk metallic glasses, by compression experiment and molecular dynamics simulations. From the simulation, we found that the large, solvent atom, Zr, has high propensity of bond exchange compared to those of the smaller solute atoms. The difference in bond exchange is consistent with the observed disparity in mechanical behaviors: Zr-rich metallic glass exhibits low elastic modulus and large plastic strain. X-ray photoelectron spectroscopy measurements suggest that the increased propensity in bond exchange is related to the softening of Zr bonds with increasing Zr content.

  16. Metal thin film growth on multimetallic surfaces: From quaternary metallic glass to binary crystal

    SciTech Connect (OSTI)

    Jing, Dapeng

    2010-01-01

    The work presented in this thesis mainly focuses on the nucleation and growth of metal thin films on multimetallic surfaces. First, we have investigated the Ag film growth on a bulk metallic glass surface. Next, we have examined the coarsening and decay of bilayer Ag islands on NiAl(110) surface. Third, we have investigated the Ag film growth on NiAl(110) surface using low-energy electron diffraction (LEED). At last, we have reported our investigation on the epitaxial growth of Ni on NiAl(110) surface. Some general conclusions can be drawn as follows. First, Ag, a bulk-crystalline material, initially forms a disordered wetting layer up to 4-5 monolayers on Zr-Ni-Cu-Al metallic glass. Above this coverage, crystalline 3D clusters grow, in parallel with the flatter regions. The cluster density increases with decreasing temperature, indicating that the conditions of island nucleation are far-from-equilibrium. Within a simple model where clusters nucleate whenever two mobile Ag adatoms meet, the temperature-dependence of cluster density yields a (reasonable) upper limit for the value of the Ag diffusion barrier on top of the Ag wetting layer of 0.32 eV. Overall, this prototypical study suggests that it is possible to grow films of a bulk-crystalline metal that adopt the amorphous character of a glassy metal substrate, if film thickness is sufficiently low. Next, the first study of coarsening and decay of bilayer islands has been presented. The system was Ag on NiAl(110) in the temperature range from 185 K to 250 K. The coarsening behavior, has some similarities to that seen in the Ag(110) homoepitaxial system studied by Morgenstern and co-workers. At 185 K and 205 K, coarsening of Ag islands follows a Smoluchowski ripening pathway. At 205 K and 250 K, the terrace diffusion limited Ostwald ripening dominants. The experimental observed temperature for the transition from SR to OR is 205 K. The SR exhibits anisotropic island diffusion and the OR exhibits 1D decay of island

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

    SciTech Connect (OSTI)

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

    2007-04-07

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

  18. Interactions at glass-ceramic to metal interfaces

    SciTech Connect (OSTI)

    Knorovsky, G.A.; Brow, R.K.; Watkins, R.D.; Loehman, R.E.

    1990-01-01

    Advanced pyrotechnic components can be fabricated from Ni-based superalloys with hermetic seals to high expansion lithium-silicate glass ceramics (LSGC). Prior studies have characterized the interfacial reactions in these systems necessary for good chemical bonding. Similar reactions occur when LSGCs are bonded to 300-series stainless steel except that these seals debond on cooling to room temperature. Cr-depletion (from {approximately}18 wt % to {approximately}5 wt %) from the steel interface cases an fcc-to-bcc phase transition that expands the interfacial grains and decreases their thermal expansion coefficient, putting the LSGC into tension, causing the seal to fail. 9 refs., 5 figs., 1 tab.

  19. Metal and Glass Manufacturers Reduce Costs by Increasing Energy Efficiency in Process Heating Systems

    Broader source: Energy.gov [DOE]

    Process heating plays a key role in producing steel, aluminum, and glass and in manufacturing products made from these materials. Faced with regulatory and competitive pressures to control emissions and reduce operating costs, metal and glass manufacturers are considering a variety of options for reducing overall energy consumption. As 38% of the energy used in U.S. industrial plants is consumed for process heating applications, metal and glass manufacturers are discovering that process heating technologies provide significant opportunities for improving industrial productivity, energy efficiency, and global competitiveness. This fact sheet is the first in a series to describe such opportunities that can be realized in industrial systems by conducting plant-wide assessments (PWA).

  20. Unique properties of CuZrAl bulk metallic glasses induced by microalloying

    SciTech Connect (OSTI)

    Huang, B.; Bai, H. Y.; Wang, W. H.

    2011-12-15

    We studied the glass forming abilities (GFA), mechanical, and physical properties of (CuZr){sub 92.5}Al{sub 7}X{sub 0.5} (X = La, Sm, Ce, Gd, Ho, Y, and Co) bulk metallic glasses (BMGs). We find that the GFA, mechanical, and physical properties can be markedly changed and modulated by the minor rare earth addition. The Kondo screening effect is found to exist in (CuZr){sub 92.5}Al{sub 7}Ce{sub 0.5} BMG at low temperatures and the Schottky effect exists in all the rare earth element doped BMGs. Our results indicate that the minor addition is an effective way for modulating and getting desirable properties of the BMGs. The mechanisms of the effects of the addition are discussed. The results have implications for the exploration of metallic glasses and for improving the mechanical and low temperature physical properties of BMGs.

  1. Understanding glass-forming ability through sluggish crystallization of atomically thin metallic glassy films

    SciTech Connect (OSTI)

    Sun, Y. T.; Cao, C. R.; Huang, K. Q.; Zhao, N. J.; Gu, L. E-mail: dzheng@iphy.ac.cn Zheng, D. N. E-mail: dzheng@iphy.ac.cn Wang, W. H. E-mail: dzheng@iphy.ac.cn

    2014-08-04

    The glass-forming ability (GFA) of an alloy, closely related to its ability to resist crystallization, is a crucial issue in condensed matter physics. So far, the studies on GFA are mostly statistical and empirical guides. Benefiting from the ultrahigh thermal stability of ultrathin metallic glassy film and high resolution spherical aberration-corrected transmission electron microscope, the crystallization of atomically thin ZrCu and its microalloyed ZrCuAl glasses with markedly different GFA was investigated at the atomic scale. We find the Zr diffusivity estimated from the density of nuclei is dramatically decreased by adding of Al, which is the major reason for the much better GFA of the ZrCuAl metallic glass.

  2. Guided evolution of bulk metallic glass nanostructures: A platform for designing three-dimensional electrocatalytic surfaces

    SciTech Connect (OSTI)

    Doubek, Gustavo; Sekol, Ryan C.; Li, Jinyang; Ryu, Won -Hee; Gittleson, Forrest S.; Nejati, Siamak; Moy, Eric; Reid, Candy; Carmo, Marcelo; Linardi, Marcelo; Bordeenithikasem, Punnathat; Kinser, Emily; Liu, Yanhui; Tong, Xiao; Osuji, Chinedum; Schroers, Jan; Mukherjee, Sundeep; Taylor, Andre D.

    2015-12-22

    Precise control over catalyst surface composition and structure is necessary to improve the function of electrochemical systems. To that end, bulk metallic glass (BMG) alloys with atomically dispersed elements provide a highly processable, nanoscale platform for electrocatalysis and surface modification. Here we report on nanostructures of Pt-based BMGs that are modified with various subtractive and additive processes to improve their electrochemical performance.

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

    SciTech Connect (OSTI)

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

    2010-01-01

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

  4. Deformation in metallic glasses studied by synchrotron x-ray diffraction

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

    Dmowski, Wojciech; Egami, Takeshi; Tong, Yang

    2016-01-11

    In this study, high mechanical strength is one of the superior properties of metallic glasses which render them promising as a structural material. However, understanding the process of mechanical deformation in strongly disordered matter, such as metallic glass, is exceedingly difficult because even an effort to describe the structure qualitatively is hampered by the absence of crystalline periodicity. In spite of such challenges, we demonstrate that high-energy synchrotron X-ray diffraction measurement under stress, using a two-dimensional detector coupled with the anisotropic pair-density function (PDF) analysis, has greatly facilitated the effort of unraveling complex atomic rearrangements involved in the elastic, anelastic,more » and plastic deformation of metallic glasses. Even though PDF only provides information on the correlation between two atoms and not on many-body correlations, which are often necessary in elucidating various properties, by using stress as means of exciting the system we can garner rich information on the nature of the atomic structure and local atomic rearrangements during deformation in glasses.« less

  5. Sharp semiconductor-to-metal transition of VO{sub 2} thin films on glass substrates

    SciTech Connect (OSTI)

    Jian, Jie; Chen, Aiping; Zhang, Wenrui; Wang, Haiyan

    2013-12-28

    Outstanding phase transition properties of vanadium dioxide (VO{sub 2}) thin films on amorphous glass were achieved and compared with the ones grown on c-cut sapphire and Si (111) substrates, all by pulsed laser deposition. The films on glass substrate exhibit a sharp semiconductor-to-metal transition (∼4.3 °C) at a near bulk transition temperature of ∼68.4 °C with an electrical resistance change as high as 3.2 × 10{sup 3} times. The excellent phase transition properties of the films on glass substrate are correlated with the large grain size and low defects density achieved. The phase transition properties of VO{sub 2} films on c-cut sapphire and Si (111) substrates were found to be limited by the high defect density.

  6. Orbital glass state of the nearly metallic spinel cobalt vanadate

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

    Koborinai, R.; Dissanayake, Sachith E.; Reehuis, M.; Matsuda, Masaaki; Kajita, T.; Kuwahara, H.; Lee, Seung -Hun; Katsufuji, T.

    2016-01-19

    Strain, magnetization, dielectric relaxation, and unpolarized and polarized neutron diffraction measurements were performed to study the magnetic and structural properties of spinel Co1–xV2+xO4. The strain measurement indicates that, upon cooling, ΔL/L in the order of ~10–4 starts increasing below TC, becomes maximum at Tmax, and then decreases and changes its sign at T*. Neutron measurements indicate that a collinear ferrimagnetic order develops below TC and upon further cooling noncollinear ferrimagnetic ordering occurs below Tmax. At low temperatures, the dielectric constant exhibits a frequency dependence, indicating slow dynamics. Lastly, these results indicate the existence of an orbital glassy state at lowmore » temperatures in this nearly metallic frustrated magnet.« less

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

    SciTech Connect (OSTI)

    Ken Marsden

    2007-03-01

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

  8. Mechanical Properties - Structure Correlation for Commercial Specification of Cast Particulate Metal Matrix Composites

    SciTech Connect (OSTI)

    Pradeep Rohatgi

    2002-12-31

    In this research, the effects of casting foundry, testing laboratory, surface conditions, and casting processes on the mechanical properties of A359-SiC composites were identified. To observe the effects, A359-SiC composites with 20 and 305 SiC particles were cast at three different foundries and tested at three different laboratories. The composites were cast in sand and permanent molds and tested as-cast and machined conditions. To identify the effect of the volume fraction and distribution of particles on the properties of the composites, particle distribution was determined using Clemex Image analysis systems, and particle volume fraction was determined using wet chemical analysis and Clemex Image analysis systems. The microstructure and fractured surfaces of the samples were analyzed using SEM, and EDX analysis was done to analyze chemical reaction between the particles and the matrix. The results of the tensile strengths exhibited that the tensile strengths depend on the density and porosity of the composites; in general the higher tensile strength is associated with lower porosity and higher density. In some cases, composites with lower density were higher than these with higher density. In the Al-20% SiC samples, the composites with more inclusions exhibited a lower tensile strength than the ones with fewer inclusions. This suggests that macroscopic casting defects such as micro-porosity, shrinkage porosity and inclusions appear to strongly influence the tensile strength more than the microstructure and particle distribution. The fatigue properties of A359/20 vol.% SiC composites were investigated under strain controlled conditions. Hysteresis loops obtained from strain controlled cyclic loading of 20% SiCp reinforced material did not exhibit any measurable softening or hardening. The fatigue life of Al-20% SiC heat treated alloy at a given total strain showed wide variation in fatigue life, which appeared to be related to factors such as inclusions

  9. On a solution to the problem of the poor cyclic fatigue resistance of bulk metallic glasses

    SciTech Connect (OSTI)

    Launey, Maximilien E.; Hofmann, Douglas C.; Johnson, William L.; Ritchie, Robert O.

    2009-01-09

    The recent development of metallic glass-matrix composites represents a particular milestone in engineering materials for structural applications owing to their remarkable combinations of strength and toughness. However, metallic glasses are highly susceptible to cyclic fatigue damage and previous attempts to solve this problem have been largely disappointing. Here we propose and demonstrate a microstructural design strategy to overcome this limitation by matching the microstructural length scales (of the second phase) to mechanical crack-length scales. Specifically, semi-solid processing is used to optimize the volume fraction, morphology, and size of second phase dendrites to confine any initial deformation (shear banding) to the glassy regions separating dendrite arms having length scales of {approx} 2 {micro}m, i.e., to less than the critical crack size for failure. Confinement of the damage to such interdendritic regions results in enhancement of fatigue lifetimes and increases the fatigue limit by an order of magnitude making these 'designed' composites as resistant to fatigue damage as high-strength steels and aluminum alloys. These design strategies can be universally applied to any other metallic glass systems.

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

    SciTech Connect (OSTI)

    Burningham, J.S.

    1995-08-01

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

  11. Field Evaluations of Low-Frequency SAFT-UT on Cast Stainless Steel and Dissimilar Metal Weld Components

    SciTech Connect (OSTI)

    Diaz, Aaron A.; Harris, R. V.; Doctor, Steven R.

    2008-11-01

    This report documents work performed at the Pacific Northwest National Laboratory (PNNL) in Richland, Washington, and at the Electric Power Research Institute's (EPRI) Nondestructive Examination (NDE) Center in Charlotte, North Carolina, on evalutating a low frequency ultrasonic inspection technique used for examination of cast stainless steel (CSS) and dissimilar metal (DMW) reactor piping components. The technique uses a zone-focused, multi-incident angle, low frequency (250-450 kHz) inspection protocol coupled with the synthetic aperture focusing technique (SAFT). The primary focus of this work is to provide information to the United States Nuclear Regulatory Commission on the utility, effectiveness and reliability of ultrasonic testing (UT) inspection techniques as related to the inservice ultrasonic inspection of coarse grained primary piping components in pressurized water reactors (PWRs).

  12. Coincidence of collective relaxation anomaly and specific heat peak in a bulk metallic glass-forming liquid

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

    Jaiswal, Abhishek; Podlesynak, Andrey; Ehlers, Georg; Mills, Rebecca; O'Keeffe, Stephanie; Stevick, Joseph; Kempton, James; Jelbert, Glenton; Dmowski, Wojciech; Lokshin, Konstantin; et al

    2015-07-21

    The study of multicomponent metallic liquids' relaxational behavior is still the key to understanding and improving the glass-forming abilities of bulk metallic glasses. Here, we report measurements of the collective relaxation times in a melted bulk metallic glass (LM601Zr51Cu36Ni4Al9) in the kinetic regime (Q: 1.5–4.0Å–1) using quasielastic neutron scattering. The results reveal an unusual slope change in the Angell plots of this metallic liquid's collective relaxation time around 950°C, beyond the material's melting point. Measurement of specific heat capacity also reveals a peak around the same temperature. Adams-Gibbs theory is used to rationalize the coincidence, which motivates more careful experimentalmore » and computational studies of the metallic liquids in the future.« less

  13. Coincidence of collective relaxation anomaly and specific heat peak in a bulk metallic glass-forming liquid

    SciTech Connect (OSTI)

    Jaiswal, Abhishek; Podlesynak, Andrey; Ehlers, Georg; Mills, Rebecca; O'Keeffe, Stephanie; Stevick, Joseph; Kempton, James; Jelbert, Glenton; Dmowski, Wojciech; Lokshin, Konstantin; Egami, Takeshi; Zhang, Yang

    2015-07-21

    The study of multicomponent metallic liquids' relaxational behavior is still the key to understanding and improving the glass-forming abilities of bulk metallic glasses. Here, we report measurements of the collective relaxation times in a melted bulk metallic glass (LM601Zr51Cu36Ni4Al9) in the kinetic regime (Q: 1.5–4.0Å–1) using quasielastic neutron scattering. The results reveal an unusual slope change in the Angell plots of this metallic liquid's collective relaxation time around 950°C, beyond the material's melting point. Measurement of specific heat capacity also reveals a peak around the same temperature. Adams-Gibbs theory is used to rationalize the coincidence, which motivates more careful experimental and computational studies of the metallic liquids in the future.

  14. Second-Nearest-Neighbor Correlations from Connection of Atomic Packing Motifs in Metallic Glasses and Liquids

    SciTech Connect (OSTI)

    Ding, Jun; Ma, Evan; Asta, Mark; Ritchie, Robert O.

    2015-11-30

    Using molecular dynamics simulations, we have studied the atomic correlations characterizing the second peak in the radial distribution function (RDF) of metallic glasses and liquids. The analysis was conducted from the perspective of different connection schemes of atomic packing motifs, based on the number of shared atoms between two linked coordination polyhedra. The results demonstrate that the cluster connections by face-sharing, specifically with three common atoms, are most favored when transitioning from the liquid to glassy state, and exhibit the stiffest elastic response during shear deformation. These properties of the connections and the resultant atomic correlations are generally the same for different types of packing motifs in different alloys. Splitting of the second RDF peak was observed for the inherent structure of the equilibrium liquid, originating solely from cluster connections; this trait can then be inherited in the metallic glass formed via subsequent quenching of the parent liquid through the glass transition, in the absence of any additional type of local structural order. In conclusion, increasing ordering and cluster connection during cooling, however, may tune the position and intensity of the split peaks.

  15. Peculiarities and application perspectives of metal-ion implants in glasses

    SciTech Connect (OSTI)

    Mazzoldi, P.; Gonella, F.; Arnold, G.W.; Battaglin, G.; Bertoncello, R.

    1993-12-31

    Ion implantation in insulators causes modifications in the refractive-index as a result of radiation damage, phase separation, or compound formation. As a consequence, light waveguides may be formed with interesting applications in the field of optoelectronics. Recently implantation of metals ions (e.g. silver, copper, gold, lead,...) showed the possibility of small radii colloidal particles formation, in a thin surface layer of the glass substrate. These particles exhibit an electron plasmon resonance which depends on the optical constants of the implanted metal and on the refractive-index of the glass host. The non-linear optical properties of such colloids, in particular the enhancement of optical Kerr susceptibility, suggest that the, ion implantation technique may play an important role for the production of all-optical switching devices. In this paper an analysis of the state-of-the-art of the research in this field will be presented in the framework of ion implantation in glass physics and chemistry.

  16. Second-Nearest-Neighbor Correlations from Connection of Atomic Packing Motifs in Metallic Glasses and Liquids

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

    Ding, Jun; Ma, Evan; Asta, Mark; Ritchie, Robert O.

    2015-11-30

    Using molecular dynamics simulations, we have studied the atomic correlations characterizing the second peak in the radial distribution function (RDF) of metallic glasses and liquids. The analysis was conducted from the perspective of different connection schemes of atomic packing motifs, based on the number of shared atoms between two linked coordination polyhedra. The results demonstrate that the cluster connections by face-sharing, specifically with three common atoms, are most favored when transitioning from the liquid to glassy state, and exhibit the stiffest elastic response during shear deformation. These properties of the connections and the resultant atomic correlations are generally the samemore » for different types of packing motifs in different alloys. Splitting of the second RDF peak was observed for the inherent structure of the equilibrium liquid, originating solely from cluster connections; this trait can then be inherited in the metallic glass formed via subsequent quenching of the parent liquid through the glass transition, in the absence of any additional type of local structural order. In conclusion, increasing ordering and cluster connection during cooling, however, may tune the position and intensity of the split peaks.« less

  17. 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)

    1997-09-01

    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.

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

    SciTech Connect (OSTI)

    none,

    2005-11-01

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

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

    SciTech Connect (OSTI)

    Baer, W.; Pusch, G.

    1995-12-31

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

  20. Casting fine grained, fully dense, strong inorganic materials

    SciTech Connect (OSTI)

    Brown, Sam W.; Spencer, Larry S.; Phillips, Michael R.

    2015-11-24

    Methods and apparatuses for casting inorganic materials are provided. The inorganic materials include metals, metal alloys, metal hydrides and other materials. Thermal control zones may be established to control the propagation of a freeze front through the casting. Agitation from a mechanical blade or ultrasonic energy may be used to reduce porosity and shrinkage in the casting. After solidification of the casting, the casting apparatus may be used to anneal the cast part.

  1. Microyielding of core-shell crystal dendrites in a bulk-metallic-glass matrix composite

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

    Huang, E. -Wen; Qiao, Junwei; Winiarski, Bartlomiej; Lee, Wen -Jay; Scheel, Mario; Chuang, Chih -Pin; Liaw, Peter K.; Lo, Yu -Chieh; Zhang, Yong; Di Michiel, Marco

    2014-03-18

    In-situ synchrotron x-ray experiments have been used to follow the evolution of the diffraction peaks for crystalline dendrites embedded in a bulk metallic glass matrix subjected to a compressive loading-unloading cycle. We observe irreversible diffraction-peak splitting even though the load does not go beyond half of the bulk yield strength. The chemical analysis coupled with the transmission electron microscopy mapping suggests that the observed peak splitting originates from the chemical heterogeneity between the core (major peak) and the stiffer shell (minor peak) of the dendrites. A molecular dynamics model has been developed to compare the hkl-dependent microyielding of the bulkmore » metallic-glass matrix composite. As a result, the complementary diffraction measurements and the simulation results suggest that the interfaces between the amorphous matrix and the (211) crystalline planes relax under prolonged load that causes a delay in the reload curve which ultimately catches up with the original path.« less

  2. Strip casting apparatus and method

    DOE Patents [OSTI]

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

    1988-09-20

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

  3. Strip casting apparatus and method

    DOE Patents [OSTI]

    Williams, Robert S.; Baker, Donald F.

    1988-01-01

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

  4. Uranium at Y-12: Casting | Y-12 National Security Complex

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

    Casting Uranium at Y-12: Casting Posted: July 22, 2013 - 3:42pm | Y-12 Report | Volume 10, Issue 1 | 2013 Buttons and other recycled metal are used in casting components for ...

  5. Deformation-induced spatiotemporal fluctuation, evolution and localization of strain fields in a bulk metallic glass

    SciTech Connect (OSTI)

    Wu, Yuan; Bei, Hongbin; Wang, Yanli; Lu, Zhaoping; George, Easo P.; Gao, Yanfei

    2015-05-16

    Deformation behavior and local strain evolutions upon loading and unloading of a bulk metallic glass (BMG) were systematically investigated by in situ digital image correlation (DIC). Distinct fluctuations and irreversible local strains were observed before the onset of macroscopic yielding. Statistical analysis shows that these fluctuations might be related to intrinsic structural heterogeneities, and that the evolution history and characteristics of local strain fields play an important role in the subsequent initiation of shear bands. Effects of sample size, pre-strain, and loading conditions were systematically analyzed in terms of the probability distributions of the resulting local strain fields. It is found that a higher degree of local shear strain heterogeneity corresponds to a more ductile stressestrain curve. Implications of these findings are discussed for the design of new materials.

  6. Deformation-induced spatiotemporal fluctuation, evolution and localization of strain fields in a bulk metallic glass

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

    Wu, Yuan; Bei, Hongbin; Wang, Yanli; Lu, Zhaoping; George, Easo P.; Gao, Yanfei

    2015-05-16

    Deformation behavior and local strain evolutions upon loading and unloading of a bulk metallic glass (BMG) were systematically investigated by in situ digital image correlation (DIC). Distinct fluctuations and irreversible local strains were observed before the onset of macroscopic yielding. Statistical analysis shows that these fluctuations might be related to intrinsic structural heterogeneities, and that the evolution history and characteristics of local strain fields play an important role in the subsequent initiation of shear bands. Effects of sample size, pre-strain, and loading conditions were systematically analyzed in terms of the probability distributions of the resulting local strain fields. It ismore » found that a higher degree of local shear strain heterogeneity corresponds to a more ductile stressestrain curve. Implications of these findings are discussed for the design of new materials.« less

  7. Smoothing metallic glasses without introducing crystallization by gas cluster ion beam

    SciTech Connect (OSTI)

    Shao, Lin; Chen, Di; Myers, Michael; Wang, Jing; Tilakaratne, Buddhi; Wijesundera, Dharshana; Chu, Wei-Kan; Xie, Guoqiang; Zare, Arezoo; Lucca, Don A.

    2013-03-11

    We show that 30 keV Ar cluster ion bombardment of Ni{sub 52.5}Nb{sub 10}Zr{sub 15}Ti{sub 15}Pt{sub 7.5} metallic glass (MG) can remove surface mountain-like features and reduce the root mean square surface roughness from 12 nm to 0.7 nm. X-ray diffraction analysis reveals no crystallization after cluster ion irradiation. Molecular dynamics simulations show that, although damage cascades lead to local melting, the subsequent quenching rate is a few orders of magnitude higher than the critical cooling rate for MG formation, thus the melted zone retains its amorphous nature down to room temperature. These findings can be applied to obtain ultra-smooth MGs without introducing crystallization.

  8. MOLDS FOR CASTING PLUTONIUM

    DOE Patents [OSTI]

    Anderson, J.W.; Miley, F.; Pritchard, W.C.

    1962-02-27

    A coated mold for casting plutonium comprises a mold base portion of a material which remains solid and stable at temperatures as high as the pouring temperature of the metal to be cast and having a thin coating of the order of 0.005 inch thick on the interior thereof. The coating is composed of finely divided calcium fluoride having a particle size of about 149 microns. (AEC)

  9. System performance and cost sensitivity comparisons of stretched membrane heliostat reflectors with current generation glass/metal concepts

    SciTech Connect (OSTI)

    Murphy, L.M.; Anderson, J.V.; Short, W.; Wendelin, T.

    1985-12-01

    Heliostat costs have long been recognized as a major factor in the cost of solar central receiver plants. Research on stretched membrane heliostats has been emphasized because of their potential as a cost-effective alternative to current glass/metal designs. However, the cost and performance potential of stretched membrane heliostats from a system perspective has not been studied until this time. The optical performance of individual heliostats is predicted here using results established in previous structural studies. These performance predictions are used to compare both focused and unfocused stretched membrane heliostats with state-of-the-art glass/metal heliostats from a systems perspective. We investigated the sensitivity of the relative cost and performance of fields of heliostats to a large number of parameter variations, including system size, delivery temperature, heliostat module size, surface specularity, hemispherical reflectance, and macroscopic surface quality. The results indicate that focused stretched membrane systems should have comparable performance levels to those of current glass/metal heliostat systems. Further, because of their relatively lower cost, stretched membrane heliostats should provide an economically attractive alternative to current glass/metal heliostats over essentially the entire range of design parameters studied. Unfocused stretched membrane heliostats may also be attractive for a somewhat more limited range of applications, including the larger plant sizes and lower delivery temperatures.

  10. Improvement of the Lost Foam Casting Process

    Broader source: Energy.gov [DOE]

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

  11. Strength statistics of single crystals and metallic glasses under small stressed volumes

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

    Gao, Yanfei; Bei, Hongbin

    2016-05-13

    It has been well documented that plastic deformation of crystalline and amorphous metals/alloys shows a general trend of “smaller is stronger”. The majority of the experimental and modeling studies along this line have been focused on finding and reasoning the scaling slope or exponent in the logarithmic plot of strength versus size. In contrast to this view, here we show that the universal picture should be the thermally activated nucleation mechanisms in small stressed volume, the stochastic behavior as to find the weakest links in intermediate sizes of the stressed volume, and the convolution of these two mechanisms with respectmore » to variables such as indenter radius in nanoindentation pop-in, crystallographic orientation, pre-strain level, sample length as in uniaxial tests, and others. Furthermore, experiments that cover the entire spectrum of length scales and a unified model that treats both thermal activation and spatial stochasticity have discovered new perspectives in understanding and correlating the strength statistics in a vast of observations in nanoindentation, micro-pillar compression, and fiber/whisker tension tests of single crystals and metallic glasses.« less

  12. DEVELOPMENT OF GLASS COMPOSITIONS TO IMMOBILIZE ALKALI, ALKALINE EARTH, LANTHANIDE AND TRANSITION METAL FISSION PRODUCTS FROM NUCLEAR FUEL REPROCESSING

    SciTech Connect (OSTI)

    Marra, J.; Billings, A.

    2009-06-24

    The Advanced Fuel Cycle Initiative (AFCI) waste management strategy revolves around specific treatment of individual or groups of separated waste streams. A goal for the separations processes is to efficiently manage the waste to be dispositioned as high level radioactive waste. The Advanced Fuel Cycle Initiative (AFCI) baseline technology for immobilization of the lanthanide (Ln) and transition metal fission product (TM) wastes is vitrification into a borosilicate glass. A current interest is to evaluate the feasibility of vitrifying combined waste streams to most cost effectively immobilize the wastes resulting from aqueous fuel reprocessing. Studies showed that high waste loadings are achievable for the Ln only (Option 1) stream. Waste loadings in excess of 60 wt % (on a calcined oxide basis) were demonstrated via a lanthanide borosilicate (LaBS) glass. The resulting glasses had excellent relative durability as determined by the Product Consistency Test (PCT). For a combined Ln and TM waste stream glass (Option 2), noble metal solubility was found to limit waste loading. However, the measured PCT normalized elemental releases for this glass were at least an order of magnitude below that of Environmental Assessment (EA) glass. Current efforts to evaluate the feasibility of vitrifying combined Ln, TM, alkali (Cs is the primary radionuclide of concern) and alkaline earth (Sr is the primary radionuclide of concern) wastes (Option 3) have shown that these approaches are feasible. However, waste loading limitations with respect to heat load (Cs/Sr loading), molybdenum solubility and/or noble metal solubility will likely be realized and must be considered in determining the cost effectiveness of these approaches.

  13. DEVELOPMENT OF GLASS COMPOSITIONS TO IMMOBILIZE ALKALI, ALKALINE EARTH, LANTHANIDE AND TRANSITION METAL FISSION PRODUCTS FROM NUCLEAR FUEL REPROCESSING

    SciTech Connect (OSTI)

    Marra, James C.; Billings, Amanda Y.; Crum, Jarrod V.; Ryan, Joseph V.; Vienna, John D.

    2010-02-26

    The Advanced Fuel Cycle Initiative (AFCI) waste management strategy revolves around specific treatment of individual or groups of separated waste streams. A goal for the separations processes is to efficiently manage the waste to be dispositioned as high level radioactive waste. The Advanced Fuel Cycle Initiative (AFCI) baseline technology for immobilization of the lanthanide (Ln) and transition metal fission product (TM) wastes is vitrification into a borosilicate glass. A current interest is to evaluate the feasibility of vitrifying combined waste streams to most cost effectively immobilize the wastes resulting from aqueous fuel reprocessing. Studies showed that high waste loadings are achievable for the Ln only (Option 1) stream. Waste loadings in excess of 60 wt % (on a calcined oxide basis) were demonstrated via a lanthanide borosilicate (LaBS) glass. The resulting glasses had excellent relative durability as determined by the Product Consistency Test (PCT). For a combined Ln and TM waste stream glass (Option 2), noble metal solubility was found to limit waste loading. However, the measured PCT normalized elemental releases for this glass were at least an order of magnitude below that of Environmental Assessment (EA) glass. Current efforts to evaluate the feasibility of vitrifying combined Ln, TM, alkali (Cs is the primary radionuclide of concern) and alkaline earth (Sr is the primary radionuclide of concern) wastes (Option 3) have shown that these approaches are feasible. However, waste loading limitations with respect to heat load (Cs/Sr loading), molybdenum solubility and/or noble metal solubility will likely be realized and must be considered in determining the cost effectiveness of these approaches.

  14. Magnetocaloric effect in heavy rare-earth elements doped Fe-based bulk metallic glasses with tunable Curie temperature

    SciTech Connect (OSTI)

    Li, Jiawei; Huo, Juntao; Chang, Chuntao E-mail: dujun@nimte.ac.cn; Du, Juan E-mail: dujun@nimte.ac.cn; Man, Qikui; Wang, Xinmin; Li, Run-Wei; Law, Jiayan

    2014-08-14

    The effects of heavy rare earth (RE) additions on the Curie temperature (T{sub C}) and magnetocaloric effect of the Fe-RE-B-Nb (RE = Gd, Dy and Ho) bulk metallic glasses were studied. The type of dopping RE element and its concentration can easily tune T{sub C} in a large temperature range of 120 K without significantly decreasing the magnetic entropy change (ΔS{sub M}) and refrigerant capacity (RC) of the alloys. The observed values of ΔS{sub M} and RC of these alloys compare favorably with those of recently reported Fe-based metallic glasses with enhanced RC compared to Gd{sub 5}Ge{sub 1.9}Si{sub 2}Fe{sub 0.1}. The tunable T{sub C} and large glass-forming ability of these RE doped Fe-based bulk metallic glasses can be used in a wide temperature range with the final required shapes.

  15. Roles of nanoclusters in shear banding and plastic deformation of bulk metallic glasses

    SciTech Connect (OSTI)

    Nieh, T.G.

    2012-07-31

    During the course of this research we published 33 papers in various physics/material journals. We select four representing papers in this report and their results are summarized as follows. I. To study shear banding process, it is pertinent to know the intrinsic shear strain rate within a propagating shear band. To this aim, we used nanoindentation technique to probe the mechanical response of a Au49Ag5.5Pd2.3Cu26.9Si16.3 bulk metallic glass in locality and found notable pop-in events associated with shear band emission. Using a free volume model and under the situation when temperature and stress/hardness are fixed result in an equation, which predicts that hardness serration caused by pop-in decreases exponentially with the strain rate. Our data are in good agreement with the prediction. The result also predicts that, when strain rate is higher than a critical strain rate of 1700 s^-1, there will be no hardness serration, thereby no pop-in. In other words, multiple shear bandings will take place and material will flow homogeneously. The critical strain rate of 1700 s^-1 can be treated as the intrinsic strain rate within a shear band. We subsequently carried out a simulation study and showed that, if the imposed strain rate was over , the shear band spacing would become so small that the entire sample would virtually behave like one major shear band. Using the datum strain rate =1700 s^-1 and based on a shear band nucleation model proposed by us, the size of a shear-band nucleus in Au-BMG was estimated to be 3 ???? 10^6 atoms, or a sphere of ~30 nm in diameter. II. Inspired by the peculiar result published in a Science article ?¢????Super Plastic Bulk Metallic Glasses at Room Temperature?¢???, we synthesized the Zr-based bulk metallic glass with a composition identical to that in the paper (Zr64.13Cu15.75Ni10.12Al10) and, subsequently, tested in compression at the same slow strain rate (~10^-4 s^-1). We found that the dominant deformation mode is

  16. Looking for footprint of bulk metallic glass in electronic and phonon heat capacities of Cu{sub 55}Hf{sub 45?x}Ti{sub x} alloys

    SciTech Connect (OSTI)

    Remenyi, G.; Biljakovi?, K.; Stareini?, D.; Dominko, D.; Risti?, R.; Babi?, E.; Figueroa, I. A.; Davies, H. A.

    2014-04-28

    We report on the heat capacity investigation of Cu{sub 55}Hf{sub 45?x}Ti{sub x} metallic glasses. The most appropriate procedure to estimate low temperature electronic and phonon contributions has been determined. Both contributions exhibit monotonous Ti concentration dependence, demonstrating that there is no relation of either the electron density of states at the Fermi level or the Debye temperature to the increased glass forming ability in the Ti concentration range x?=?1530. The thermodynamic parameters (e.g., reduced glass temperature) remain better indicators in assessing the best composition for bulk metallic glass formation.

  17. Comparison of costs for solidification of high-level radioactive waste solutions: glass monoliths vs metal matrices

    SciTech Connect (OSTI)

    Jardine, L.J.; Carlton, R.E.; Steindler, M.J.

    1981-05-01

    A comparative economic analysis was made of four solidification processes for liquid high-level radioactive waste. Two processes produced borosilicate glass monoliths and two others produced metal matrix composites of lead and borosilicate glass beads and lead and supercalcine pellets. Within the uncertainties of the cost (1979 dollars) estimates, the cost of the four processes was about the same, with the major cost component being the cost of the primary building structure. Equipment costs and operating and maintenance costs formed only a small portion of the building structure costs for all processes.

  18. Loading-rate-independent delay of catastrophic avalanches in a bulk metallic glass

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

    Chen, S. H.; Chan, K. C.; Wang, G.; Wu, F. F.; Xia, L.; Ren, J. L.; Li, J.; Dahmen, K. A.; Liaw, P. K.

    2016-02-25

    The plastic flow of bulk metallic glasses (BMGs) is characterized by intermittent bursts of avalanches, and this trend results in disastrous failures of BMGs. In the present work, a double-side-notched BMG specimen is designed, which exhibits chaotic plastic flows consisting of several catastrophic avalanches under the applied loading. The disastrous shear avalanches have, then, been delayed by forming a stable plastic-flow stage in the specimens with tailored distances between the bottoms of the notches, where the distribution of a complex stress field is acquired. Differing from the conventional compressive testing results, such a delaying process is independent of loading rate.more » The statistical analysis shows that in the specimens with delayed catastrophic failures, the plastic flow can evolve to a critical dynamics, making the catastrophic failure more predictable than the ones with chaotic plastic flows. Lastly, the findings are of significance in understanding the plastic-flow mechanisms in BMGs and controlling the avalanches in relating solids.« less

  19. Zr-based bulk metallic glass as a cylinder material for high pressure apparatuses

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

    Komatsu, Kazuki; Munakata, Koji; Matsubayashi, Kazuyuki; Uwatoko, Yoshiya; Yokoyama, Yoshihiko; Sugiyama, Kazumasa; Matsuda, Masaaki

    2015-05-12

    Zirconium-based bulk metallic glass (Zr-based BMG) has outstanding properties as a cylinder mate- rial for piston-cylinder high pressure apparatuses and is especially useful for neutron scattering. The piston-cylinder consisting of a Zr-based BMG cylinder with outer/inner diameters of 8.8/2.5 mm sustains pressures up to 1.81 GPa and ruptured at 2.0 GPa, with pressure values determined by the superconduct- ing temperature of lead. The neutron attenuation of Zr-based BMG is similar to that of TiZr null-scattering alloy and more transparent than that of CuBe alloy. No contamination of sharp Bragg reflections is observed in the neutron diffraction pattern for Zr-based BMG.more » The magnetic susceptibility of Zr-based BMG is similar to that of CuBe alloy; this leads to a potential application for measurements of magnetic properties under pressure.« less

  20. Effects of helium implantation on the tensile properties and microstructure of Ni??P?? metallic glass nanostructures

    SciTech Connect (OSTI)

    Liontas, Rachel; Gu, X. Wendy; Fu, Engang; Wang, Yongqiang; Li, Nan; Mara, Nathan; Greer, Julia R.

    2014-09-10

    We report fabrication and nanomechanical tension experiments on as-fabricated and helium-implanted ~130 nm diameter Ni??P?? metallic glass nano-cylinders. The nano-cylinders were fabricated by a templated electroplating process and implanted with He? at energies of 50, 100, 150, and 200 keV to create a uniform helium concentration of ~3 at. % throughout the nano-cylinders. Transmission electron microscopy (TEM) imaging and through-focus analysis reveal that the specimens contained ~2 nm helium bubbles distributed uniformly throughout the nano-cylinder volume. In-situ tensile experiments indicate that helium-implanted specimens exhibit enhanced ductility as evidenced by a 2-fold increase in plastic strain over as-fabricated specimens, with no sacrifice in yield and ultimate tensile strengths. This improvement in mechanical properties suggests that metallic glasses may actually exhibit a favorable response to high levels of helium implantation.

  1. Effects of helium implantation on the tensile properties and microstructure of Ni₇₃P₂₇ metallic glass nanostructures

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

    Liontas, Rachel; Gu, X. Wendy; Fu, Engang; Wang, Yongqiang; Li, Nan; Mara, Nathan; Greer, Julia R.

    2014-09-10

    We report fabrication and nanomechanical tension experiments on as-fabricated and helium-implanted ~130 nm diameter Ni₇₃P₂₇ metallic glass nano-cylinders. The nano-cylinders were fabricated by a templated electroplating process and implanted with He⁺ at energies of 50, 100, 150, and 200 keV to create a uniform helium concentration of ~3 at. % throughout the nano-cylinders. Transmission electron microscopy (TEM) imaging and through-focus analysis reveal that the specimens contained ~2 nm helium bubbles distributed uniformly throughout the nano-cylinder volume. In-situ tensile experiments indicate that helium-implanted specimens exhibit enhanced ductility as evidenced by a 2-fold increase in plastic strain over as-fabricated specimens, with nomore » sacrifice in yield and ultimate tensile strengths. This improvement in mechanical properties suggests that metallic glasses may actually exhibit a favorable response to high levels of helium implantation.« less

  2. Energy Consumption of Die Casting Operations

    SciTech Connect (OSTI)

    Jerald Brevick; clark Mount-Campbell; Carroll Mobley

    2004-03-15

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

  3. Fillability of Thin-Wall Steel Castings

    SciTech Connect (OSTI)

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

    2002-07-30

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

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

    SciTech Connect (OSTI)

    Not Available

    2003-09-01

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

  5. Bioactive Glass Scaffolds for Bone Regeneration

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

    have been used for the fabrication of glass scaffolds, including polymer foam replication, sol-gel, and freeze-casting; however, the low compressive strength of these...

  6. Local Probe into the Atomic Structure of Metallic Glasses using EELS

    SciTech Connect (OSTI)

    Alamgir, F.M.; Ito, Y. Schwarz, R.B.

    1999-11-30

    Electron energy loss spectroscopy (EELS) is used to extract information on the topological arrangement of atoms around Pd in the bulk-glass-forming Pd{sub 60}Ni{sub 20}P{sub 20}. It is found that the environment around Pd in the glass is only a slight modification of the Pd crystalline structure. However, the modification is enough to allow this alloy to form a glass in bulk. In examining the differences between the structure of crystalline Pd and glassy Pd{sub 60}Ni{sub 20}P{sub 20} it is concluded that incorporation of Ni and P into the structure frustrates the structure enough that glass formation becomes easy.

  7. A new method for separating first row transition metals and actinides from synthetic melt glass

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

    Roman, Audrey Rae; Bond, Evelyn M.

    2016-01-14

    A new method was developed for separating Co, Fe, and Sc from complex debris matrices using the extraction chromatography resin DGA. The activation products Co-58, Mn-54, and Sc-46 were used to characterize the separation of the synthetic melt glass solutions. In the separation scheme that was developed, Au, Co, Cu, Fe, Sc, and Ti were separated from the rest of the sample constituents. In this paper, the synthetic melt glass separation method, efficiency, recoveries, and the length of procedure will be discussed. In conclusion, batch contact adsorption studies for Na and Sc for DGA resin are discussed as well.

  8. Chemically durable nitrogen containing phosphate glasses useful for sealing to metals

    DOE Patents [OSTI]

    Day, Delbert E.; Wilder, Jr., James A.

    1984-01-01

    The chemical durability of alkali phosphate glasses is improved by incorporation of up to 23 weight percent of nitrogen. A typical phosphate glass contains: 10 to 60 mole % of Li.sub.2 O, Na.sub.2 O or K.sub.2 O; 5-40 mole % of BaO or CAO; 0-1 to 10 mole % of Al.sub.2 O.sub.3 ; and 40-70 mole % of P.sub.2 O.sub.5. Nitrides, such as AlN, are the favored additives.

  9. Optimization of Squeeze Casting for Aluminum Alloy Parts (Technical...

    Office of Scientific and Technical Information (OSTI)

    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 ...

  10. Noble Metals and Spinel Settling in High Level Waste Glass Melters

    SciTech Connect (OSTI)

    Sundaram, S. K.; Perez, Joseph M.

    2000-09-30

    In the continuing effort to support the Defense Waste Processing Facility (DWPF), the noble metals issue is addressed. There is an additional concern about the amount of noble metals expected to be present in the future batches that will be considered for vitrification in the DWPF. Several laboratory, as well as melter-scale, studies have been completed by various organizations (mainly PNNL, SRTC, and WVDP in the USA). This letter report statuses the noble metals issue and focuses at the settling of noble metals in melters.

  11. CASTING FURNACES

    DOE Patents [OSTI]

    Ruppel, R.H.; Winters, C.E.

    1961-01-01

    A device is described for casting uranium which comprises a crucible, a rotatable table holding a plurality of molds, and a shell around both the crucible and the table. The bottom of the crucible has an eccentrically arranged pouring hole aligned with one of the molds at a time. The shell can be connected with a vacuum.

  12. Strip casting with fluxing agent applied to casting roll

    SciTech Connect (OSTI)

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

    1997-07-29

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

  13. Strip casting with fluxing agent applied to casting roll

    DOE Patents [OSTI]

    Williams, Robert S.; O'Malley, Ronald J.; Sussman, Richard C.

    1997-01-01

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

  14. Laser shock peening on Zr-based bulk metallic glass and its effect on plasticity: Experiment and modeling

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

    Cao, Yunfeng; Xie, Xie; Antonaglia, James; Winiarski, Bartlomiej; Wang, Gongyao; Shin, Yung C.; Withers, Philip J.; Dahmen, Karin A.; Liaw, Peter K.

    2015-05-20

    The Zr-based bulk metallic glasses (BMGs) are a new family of attractive materials with good glass-forming ability and excellent mechanical properties, such as high strength and excellent wear resistance, which make them candidates for structural and biomedical materials. Although the mechanical behavior of BMGs has been widely investigated, their deformation mechanisms are still poorly understood. In particular, their poor ductility significantly impedes their industrial application. In the present work, we show that the ductility of Zr-based BMGs with nearly zero plasticity is improved by a laser shock peening technique. Moreover, we map the distribution of laser-induced residual stresses via themore » micro-slot cutting method, and then predict them using a three dimensional finite-element method coupled with a confined plasma model. Reasonable agreement is achieved between the experimental and modeling results. The analysis of serrated flow reveals plentiful and useful information of the underlying deformation process. As a result, our work provides an easy and effective way to extend the ductility of intrinsically-brittle BMGs, opening up wider applications of these materials.« less

  15. Laser shock peening on Zr-based bulk metallic glass and its effect on plasticity: Experiment and modeling

    SciTech Connect (OSTI)

    Cao, Yunfeng; Xie, Xie; Antonaglia, James; Winiarski, Bartlomiej; Wang, Gongyao; Shin, Yung C.; Withers, Philip J.; Dahmen, Karin A.; Liaw, Peter K.

    2015-05-20

    The Zr-based bulk metallic glasses (BMGs) are a new family of attractive materials with good glass-forming ability and excellent mechanical properties, such as high strength and excellent wear resistance, which make them candidates for structural and biomedical materials. Although the mechanical behavior of BMGs has been widely investigated, their deformation mechanisms are still poorly understood. In particular, their poor ductility significantly impedes their industrial application. In the present work, we show that the ductility of Zr-based BMGs with nearly zero plasticity is improved by a laser shock peening technique. Moreover, we map the distribution of laser-induced residual stresses via the micro-slot cutting method, and then predict them using a three dimensional finite-element method coupled with a confined plasma model. Reasonable agreement is achieved between the experimental and modeling results. The analysis of serrated flow reveals plentiful and useful information of the underlying deformation process. As a result, our work provides an easy and effective way to extend the ductility of intrinsically-brittle BMGs, opening up wider applications of these materials.

  16. Insulating and metallic spin glass in Ni-doped KxFe2-ySe? single crystals

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

    Ryu, Hyejin; Abeykoon, Milinda; Wang, Kefeng; Lei, Hechang; Lazarevic, N.; Warren, J. B.; Bozin, E. S.; Popovic, Z. V.; Petrovic, C.

    2015-05-04

    We report electron doping effects by Ni in KxFe2-?-yNiySe? (0.06 ? y ? 1.44) single crystal alloys. A rich ground state phase diagram is observed. A small amount of Ni (~ 4%) suppressed superconductivity below 1.8 K, inducing insulating spin glass magnetic ground state for higher Ni content. With further Ni substitution, metallic resistivity is restored. For high Ni concentration in the lattice the unit cell symmetry is high symmetry I4/mmm with no phase separation whereas both I4/m + I4/mmm space groups were detected in the phase separated crystals when concentration of Ni morewith the absence of crystalline Fe vacancy order.less

  17. Enhanced sensitivity of Raman spectroscopy for tritium gas analysis using a metal-lined hollow glass fiber

    SciTech Connect (OSTI)

    Rupp, S.; Schloesser, M.; Bornschein, B.; James, T.M.; Telle, H.H.

    2015-03-15

    The precise compositional analysis of tritium-containing gases is of high interest for tritium accountancy in future fusion power plants. Raman spectroscopy provides a fast and contact-free gas analysis procedure with high precision, thus being an advantageous tool for the named purpose. In this paper, it is shown that the sensitivity achieved with conventional Raman systems (in 90 degrees or forward/backward configurations) can be enhanced by at least one order of magnitude by using a metal-lined hollow glass fiber as the Raman cell. This leads to the ability of detecting low partial pressures of tritium within short measurement intervals (< 0.5 mbar in < 0.5 s) opening the way for real-time applications.

  18. Insulating and metallic spin glass in Ni-doped K x Fe 2 - y Se 2 single crystals

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

    Ryu, Hyejin; Abeykoon, Milinda; Wang, Kefeng; Lei, Hechang; Lazarevic, N.; Warren, J. B.; Bozin, E. S.; Popovic, Z. V.; Petrovic, C.

    2015-05-04

    We report electron doping effects by Ni in KxFe2-δ-yNiySe₂(0.06≤y≤1.44) single-crystal alloys. A rich ground-state phase diagram is observed. A small amount of Ni (~4%) suppressed superconductivity below 1.8 K, inducing insulating spin-glass magnetic ground state for higher Ni content. With further Ni substitution, metallic resistivity is restored. For high Ni concentration in the lattice the unit cell symmetry is high symmetry I4/mmm with no phase separation whereas both I4/m+I4/mmm space groups were detected in the phase separated crystals when concentration of Ni < Fe. The absence of superconductivity coincides with the absence of crystalline Fe vacancy order.

  19. Effect of geometrical constraint condition on the formation of nanoscale twins in the Ni-based metallic glass composite

    SciTech Connect (OSTI)

    Lee, M.H.; Kim, B.S.; Kim, D.H.; Ott, R.T.; Sansoz, F.; Eckert, J.

    2014-04-25

    We investigated the effect of geometrically constrained stress-strain conditions on the formation of nanotwins in alpha-brass phase reinforced Ni59Zr20Ti16Si2Sn3 metallic glass (MG) matrix deformed under macroscopic uniaxial compression. The specific geometrically constrained conditions in the samples lead to a deviation from a simple uniaxial state to a multi-axial stress state, for which nanocrystallization in the MG matrix together with nanoscale twinning of the brass reinforcement is observed in localized regions during plastic flow. The nanocrystals in the MG matrix and the appearance of the twinned structure in the reinforcements indicate that the strain energy is highly confined and the local stress reaches a very high level upon yielding. Both the effective distribution of reinforcements on the strain enhancement of composite and the effects of the complicated stress states on the development of nanotwins in the second-phase brass particles are discussed.

  20. Direct synchrotron x-ray measurements of local strain fields in elastically and plastically bent metallic glasses

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

    Wu, Yuan; Stoica, Alexandru Dan; Ren, Yang; Ma, Dong; Gao, Yanfei F.; Bei, Hongbin

    2015-09-03

    In situ high-energy synchrotron X-ray diffraction was conducted on elastically and plastically bent bulk metallic glass (BMG) thin plates, from which distinct local elastic strain fields were mapped spatially. These directly measured residual strain fields can be nicely interpreted by our stress analysis, and also validate a previously proposed indirect residual-stress-measurement method by relating nanoindentation hardness to residual stresses. Local shear strain variations on the cross sections of these thin plates were found in the plastically bent BMG, which however cannot be determined from the indirect indentation method. As a result, this study has important implications in designing and manipulatingmore » internal strain fields in BMGs for the purpose of ductility enhancement.« less

  1. Direct synchrotron x-ray measurements of local strain fields in elastically and plastically bent metallic glasses

    SciTech Connect (OSTI)

    Wu, Yuan; Stoica, Alexandru Dan; Ren, Yang; Ma, Dong; Gao, Yanfei F.; Bei, Hongbin

    2015-09-03

    In situ high-energy synchrotron X-ray diffraction was conducted on elastically and plastically bent bulk metallic glass (BMG) thin plates, from which distinct local elastic strain fields were mapped spatially. These directly measured residual strain fields can be nicely interpreted by our stress analysis, and also validate a previously proposed indirect residual-stress-measurement method by relating nanoindentation hardness to residual stresses. Local shear strain variations on the cross sections of these thin plates were found in the plastically bent BMG, which however cannot be determined from the indirect indentation method. As a result, this study has important implications in designing and manipulating internal strain fields in BMGs for the purpose of ductility enhancement.

  2. Casting methods

    DOE Patents [OSTI]

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

    2012-12-18

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

  3. Bio-corrosion and cytotoxicity studies on novel Zr55Co30Ti15 and Cu60Zr20Ti20 metallic glasses

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

    Vincent, S.; Daiwile, A.; Devi, S. S.; Kramer, M. J.; Besser, M. F.; Murty, B. S.; Bhatt, Jatin

    2014-09-26

    Metallic glasses are a potential and compatible implant candidate for biomedical applications. In the present investigation, a comparative study between novel Zr55Co30Ti15 and Cu60Zr20Ti20 metallic glasses is carried out to evaluate in vitro biocompatibility using simulated body fluids. The bio-corrosion behavior of Zr- and Cu-based metallic glasses in different types of artificial body fluids such as artificial saliva solution, phosphate-buffered saline solution, artificial blood plasma solution, and Hank’s balanced saline solution is evaluated using potentiodynamic polarization studies at a constant body temperature of 310.15 K (37 °C). Surface morphology of samples after bio-corrosion experiments was observed by scanning electron microscopy.more » In vitro cytotoxicity test on glassy alloys were performed using human osteosarcoma cell line as per 10993-5 guidelines from International Organization for Standardization. As a result, the comparative study between Zr- and Cu-based glassy alloys provides vital information about the effect of elemental composition on biocompatibility of metallic glasses.« less

  4. CASTING APPARATUS

    DOE Patents [OSTI]

    Gray, C.F.; Thompson, R.H.

    1958-09-23

    An apparatus is described for casting small quantities of uranlum. It consists of a crucible having a hole in the bottom with a mold positioned below. A vertical rcd passes through the hole in the crucible and has at its upper end a piercing head adapted to break the oxide skin encasing a molten uranium body. An air tight cylinder surrounds the crucible and mold, and is arranged to be evacuated.

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

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

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

  6. Composition-dependent stability of the medium-range order responsible for metallic glass formation

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

    Zhang, Feng; Ji, Min; Fang, Xiao-Wei; Sun, Yang; Wang, Cai-Zhuang; Mendelev, Mikhail I.; Kramer, M. J.; Napolitano, Ralph E.; Ho, Kai-Ming

    2014-09-18

    The competition between the characteristic medium-range order corresponding to amorphous alloys and that in ordered crystalline phases is central to phase selection and morphology evolution under various processing conditions. We examine the stability of a model glass system, Cu–Zr, by comparing the energetics of various medium-range structural motifs over a wide range of compositions using first-principles calculations. Furthermore, we focus specifically on motifs that represent possible building blocks for competing glassy and crystalline phases, and we employ a genetic algorithm to efficiently identify the energetically favored decorations of each motif for specific compositions. These results show that a Bergman-type motifmore » with crystallization-resisting icosahedral symmetry is energetically most favorable in the composition range 0.63 < xCu < 0.68, and is the underlying motif for one of the three optimal glass-forming ranges observed experimentally for this binary system (Li et al., 2008). This work establishes an energy-based methodology to evaluate specific medium-range structural motifs which compete with stable crystalline nuclei in deeply undercooled liquids.« less

  7. Composition-dependent stability of the medium-range order responsible for metallic glass formation

    SciTech Connect (OSTI)

    Zhang, Feng; Ji, Min; Fang, Xiao-Wei; Sun, Yang; Wang, Cai-Zhuang; Mendelev, Mikhail I.; Kramer, M. J.; Napolitano, Ralph E.; Ho, Kai-Ming

    2014-09-18

    The competition between the characteristic medium-range order corresponding to amorphous alloys and that in ordered crystalline phases is central to phase selection and morphology evolution under various processing conditions. We examine the stability of a model glass system, Cu–Zr, by comparing the energetics of various medium-range structural motifs over a wide range of compositions using first-principles calculations. Furthermore, we focus specifically on motifs that represent possible building blocks for competing glassy and crystalline phases, and we employ a genetic algorithm to efficiently identify the energetically favored decorations of each motif for specific compositions. These results show that a Bergman-type motif with crystallization-resisting icosahedral symmetry is energetically most favorable in the composition range 0.63 < xCu < 0.68, and is the underlying motif for one of the three optimal glass-forming ranges observed experimentally for this binary system (Li et al., 2008). This work establishes an energy-based methodology to evaluate specific medium-range structural motifs which compete with stable crystalline nuclei in deeply undercooled liquids.

  8. A computational study of diffusion in a glass-forming metallic liquid

    SciTech Connect (OSTI)

    Wang, T.; Zhang, F.; Yang, L.; Fang, X. W.; Zhou, S. H.; Kramer, M. J.; Wang, C. Z.; Ho, K. M.; Napolitano, R. E.

    2015-06-09

    In this study, liquid phase diffusion plays a critical role in phase transformations (e.g. glass transformation and devitrification) observed in marginal glass forming systems such as Al-Sm. Controlling transformation pathways in such cases requires a comprehensive description of diffusivity, including the associated composition and temperature dependencies. In our computational study, we examine atomic diffusion in Al-Sm liquids using ab initio molecular dynamics (AIMD) and determine the diffusivities of Al and Sm for selected alloy compositions. Non-Arrhenius diffusion behavior is observed in the undercooled liquids with an enhanced local structural ordering. Through assessment of our AIMD result, we construct a general formulation for Al-Sm liquid, involving a diffusion mobility database that includes composition and temperature dependence. A Volmer-Fulcher-Tammann (VFT) equation is adopted for describing the non-Arrhenius behavior observed in the undercooled liquid. Furthermore, the composition dependence of diffusivity is found quite strong, even for the Al-rich region contrary to the sole previous report on this binary system. The model is used in combination with the available thermodynamic database to predict specific diffusivities and compares well with reported experimental data for 0.6 at.% and 5.6 at.% Sm in Al-Sm alloys.

  9. A computational study of diffusion in a glass-forming metallic liquid

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

    Wang, T.; Zhang, F.; Yang, L.; Fang, X. W.; Zhou, S. H.; Kramer, M. J.; Wang, C. Z.; Ho, K. M.; Napolitano, R. E.

    2015-06-09

    In this study, liquid phase diffusion plays a critical role in phase transformations (e.g. glass transformation and devitrification) observed in marginal glass forming systems such as Al-Sm. Controlling transformation pathways in such cases requires a comprehensive description of diffusivity, including the associated composition and temperature dependencies. In our computational study, we examine atomic diffusion in Al-Sm liquids using ab initio molecular dynamics (AIMD) and determine the diffusivities of Al and Sm for selected alloy compositions. Non-Arrhenius diffusion behavior is observed in the undercooled liquids with an enhanced local structural ordering. Through assessment of our AIMD result, we construct a generalmore » formulation for Al-Sm liquid, involving a diffusion mobility database that includes composition and temperature dependence. A Volmer-Fulcher-Tammann (VFT) equation is adopted for describing the non-Arrhenius behavior observed in the undercooled liquid. Furthermore, the composition dependence of diffusivity is found quite strong, even for the Al-rich region contrary to the sole previous report on this binary system. The model is used in combination with the available thermodynamic database to predict specific diffusivities and compares well with reported experimental data for 0.6 at.% and 5.6 at.% Sm in Al-Sm alloys.« less

  10. A computational study of diffusion in a glass-forming metallic liquid

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

    Wang, T.; Zhang, F.; Yang, L.; Fang, X. W.; Zhou, S. H.; Kramer, M. J.; Wang, C. Z.; Ho, K. M.; Napolitano, R. E.

    2015-06-09

    Liquid phase diffusion plays a critical role in phase transformations (e.g. glass transformation and devitrification) observed in marginal glass forming systems such as Al-Sm. Controlling transformation pathways in such cases requires a comprehensive description of diffusivity, including the associated composition and temperature dependencies. In the computational study reported here, we examine atomic diffusion in Al-Sm liquids using ab initio molecular dynamics (AIMD) and determine the diffusivities of Al and Sm for selected alloy compositions. Non-Arrhenius diffusion behavior is observed in the undercooled liquids with an enhanced local structural ordering. Through assessment of our AIMD result, we construct a general formulationmorefor Al-Sm liquid, involving a diffusion mobility database that includes composition and temperature dependence. A Volmer-Fulcher-Tammann (VFT) equation is adopted for describing the non-Arrhenius behavior observed in the undercooled liquid. The composition dependence of diffusivity is found quite strong, even for the Al-rich region contrary to the sole previous report on this binary system. The model is used in combination with the available thermodynamic database to predict specific diffusivities and compares well with reported experimental data for 0.6 at.% and 5.6 at.% Sm in Al-Sm alloys.less

  11. Crystallization of Zr2PdxCu(1-x) and Zr2NixCu(1-x) Metallic Glass

    SciTech Connect (OSTI)

    Min Xu

    2008-08-18

    One interesting aspect of rretallic glasses is the numerous instances of the deviation of the phase selection from the amorphous state to thermodynamically stable phases during the crystallization process. Their devitrification pathways allow us to study the relationship between the original amorphous structure and their crystalline counter parts. Among the various factors of phase selections, size and electronic effects have been most extensively studied. Elucidating the phase selection process of a glassy alloy will be helpful to fill in the puzzle of the changes from disordered to ordered structures. In this thesis, Two model Zr{sub 2}Pd{sub x}Cu{sub (1-x)} and Zr{sub 2}Ni{sub x}Cu{sub (1-x)} (x = 0, 0.25, 0.5, 0.75 and 1) glassy systems were investigated since: (1) All of the samples can be made into a homogenous metallic glass; (2) The atomic radii differ from Pd to Cu is by 11%, while Ni has nearly the identical atomic size compare to Cu. Moreover, Pd and Ni differ by only one valence electron from Cu. Thus, these systems are ideal to test the idea of the effects of electronic structure and size factors; (3) The small number of components in these pseudo binary systems readily lend themselves to theoretical modeling. Using high temperature X-ray diffraction {HTXRD) and thermal analysis, topological, size, electronic, bond and chemical distribution factors on crystallization selections in Zr{sub 2}Pd{sub x}Cu{sub (1-x)} and Zr{sub 2}Ni{sub x}Cu{sub (1-x)} metallic glass have been explored. All Zr{sub 2}Pd{sub x}Cu{sub (1-x)} compositions share the same Cu11b phase with different pathways of meta-stable, icosahedral quasicrystalline phase (i-phase), and C16 phase formations. The quasicrystal phase formation is topologically related to the increasing icosahedral short range order (SRO) with Pd content in Zr{sub 2}Pd{sub x}Cu{sub (1·x)} system. Meta-stable C16 phase is competitive with C11b phase at x = 0.5, which is dominated by electronic structure rather than

  12. The Role of Partial Crystallinity on Hydrogen Permeation in Fe–Ni–B–Mo Based Metallic Glass Membranes

    SciTech Connect (OSTI)

    Brinkman, K.; Su, D.; Fox, E.; Korinko, P.; Missimer, D.; Adams, T.

    2011-08-15

    A potentially exciting material for membrane separations are metallic glass materials due to their low cost, high elastic toughness and resistance to hydrogen embrittlement as compared to crystalline Pd-based membrane systems. However, at elevated temperatures and extended operation times structural changes including partial crystallinity may appear in these amorphous metallic systems. This study reports on the investigation of time and temperature dependent crystalline phase formation in conjunction with in situ crystallization/hydrogen permeation experiments at elevated temperatures. At temperatures near 400 C a FeNi crystalline phase appears as 22 vol.% inside the host amorphous matrix and the resulting composite structure remains stable over 3 h at temperature. The hydrogen permeation at 400 C of the partially crystalline material is similar to the fully amorphous material near 5 x 10{sup -9} mol H{sub 2}/m s Pa{sup 1/2}, while ambient temperature electrochemical permeation at 25 C revealed an order of magnitude decrease in the permeation of partially crystalline materials due to differences in the amorphous versus crystalline phase activation energy for hydrogen permeation.

  13. Atomic-scale dynamics of a model glass-forming metallic liquid: Dynamical crossover, dynamical decoupling, and dynamical clustering

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

    Jaiswal, Abhishek; Egami, Takeshi; Zhang, Yang

    2015-04-01

    The phase behavior of multi-component metallic liquids is exceedingly complex because of the convoluted many-body and many-elemental interactions. Herein, we present systematic studies of the dynamic aspects of such a model ternary metallic liquid Cu40Zr51Al9 using molecular dynamics simulation with embedded atom method. We observed a dynamical crossover from Arrhenius to super-Arrhenius behavior in the transport properties (diffusion coefficient, relaxation times, and shear viscosity) bordered at Tx ~1300K. Unlike in many molecular and macromolecular liquids, this crossover phenomenon occurs in the equilibrium liquid state well above the melting temperature of the system (Tm ~ 900K), and the crossover temperature ismore » roughly twice of the glass-transition temperature (Tg). Below Tx, we found the elemental dynamics decoupled and the Stokes-Einstein relation broke down, indicating the onset of heterogeneous spatially correlated dynamics in the system mediated by dynamic communications among local configurational excitations. To directly characterize and visualize the correlated dynamics, we employed a non-parametric, unsupervised machine learning technique and identified dynamical clusters of atoms with similar atomic mobility. The revealed average dynamical cluster size shows an accelerated increase below Tx and mimics the trend observed in other ensemble averaged quantities that are commonly used to quantify the spatially heterogeneous dynamics such as the non-Gaussian parameter and the four-point correlation function.« less

  14. Casting materials

    DOE Patents [OSTI]

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

    2011-06-14

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

  15. Use of metallic glasses for fabrication of structures with submicron dimensions

    DOE Patents [OSTI]

    Wiley, John D.; Perepezko, John H.

    1986-01-01

    Patterned structures of submicron dimension formed of supported or unsupported amorphous metals having submicron feature sizes characterized by etching behavior sufficient to allow delineation of sharp edges and smooth flat flanks, resistance to time-dependent dimensional changes caused by creep, flow, in-diffusion of unwanted impurities, out-diffusion of constituent atoms, void formation, grain growth or phase separation and resistance to phase transformations or compound formation.

  16. Glass Membrane For Controlled Diffusion Of Gases

    DOE Patents [OSTI]

    Shelby, James E.; Kenyon, Brian E.

    2001-05-15

    A glass structure for controlled permeability of gases includes a glass vessel. The glass vessel has walls and a hollow center for receiving a gas. The glass vessel contains a metal oxide dopant formed with at least one metal selected from the group consisting of transition metals and rare earth metals for controlling diffusion of the gas through the walls of the glass vessel. The vessel releases the gas through its walls upon exposure to a radiation source.

  17. APPARATUS AND METHOD FOR INJECTION CASTING

    DOE Patents [OSTI]

    Shuck, A.B.

    1960-09-13

    S>A single-chamber metal casting apparatus is described wherein molten metal in a vertically movable container can be brought directly into contact with molds. By increasing the gas pressure within the chamber the metal is forced upward into the molds.

  18. Bose-Einstein Condensation and Bose Glasses in an S = 1 Organo-metallic quantum magnet

    SciTech Connect (OSTI)

    Zapf, Vivien

    2012-06-01

    I will speak about Bose-Einstein condensation (BEC) in quantum magnets, in particular the compound NiCl2-4SC(NH2)2. Here a magnetic field-induced quantum phase transition to XY antiferromagnetism can be mapped onto BEC of the spins. The tuning parameter for BEC transition is the magnetic field rather than the temperature. Some interesting phenomena arise, for example the fact that the mass of the bosons that condense can be strongly renormalized by quantum fluctuations. I will discuss the utility of this mapping for both understanding the nature of the quantum magnetism and testing the thermodynamic limit of Bose-Einstein Condensation. Furthermore we can dope the system in a clean and controlled way to create the long sought-after Bose Glass transition, which is the bosonic analogy of Anderson localization. I will present experiments and simulations showing evidence for a new scaling exponent, which finally makes contact between theory and experiments. Thus we take a small step towards the difficult problem of understanding the effect of disorder on bosonic wave functions.

  19. Atomic-scale dynamics of a model glass-forming metallic liquid: Dynamical crossover, dynamical decoupling, and dynamical clustering

    SciTech Connect (OSTI)

    Jaiswal, Abhishek; Egami, Takeshi; Zhang, Yang

    2015-04-01

    The phase behavior of multi-component metallic liquids is exceedingly complex because of the convoluted many-body and many-elemental interactions. Herein, we present systematic studies of the dynamic aspects of such a model ternary metallic liquid Cu40Zr51Al9 using molecular dynamics simulation with embedded atom method. We observed a dynamical crossover from Arrhenius to super-Arrhenius behavior in the transport properties (diffusion coefficient, relaxation times, and shear viscosity) bordered at Tx ~1300K. Unlike in many molecular and macromolecular liquids, this crossover phenomenon occurs in the equilibrium liquid state well above the melting temperature of the system (Tm ~ 900K), and the crossover temperature is roughly twice of the glass-transition temperature (Tg). Below Tx, we found the elemental dynamics decoupled and the Stokes-Einstein relation broke down, indicating the onset of heterogeneous spatially correlated dynamics in the system mediated by dynamic communications among local configurational excitations. To directly characterize and visualize the correlated dynamics, we employed a non-parametric, unsupervised machine learning technique and identified dynamical clusters of atoms with similar atomic mobility. The revealed average dynamical cluster size shows an accelerated increase below Tx and mimics the trend observed in other ensemble averaged quantities that are commonly used to quantify the spatially heterogeneous dynamics such as the non-Gaussian parameter and the four-point correlation function.

  20. Ab initio molecular dynamics simulations of short-range order in Zr50Cu45Al5 and Cu50Zr45Al5 metallic glasses

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

    Huang, Yuxiang; Huang, Li; Wang, C. Z.; Kramer, M. J.; Ho, K. M.

    2016-02-01

    In this study, comparative analysis between Zr-rich Zr50Cu45Al5 and Cu-rich Cu50Zr45Al5 metallic glasses (MGs) is extensively performed to locate the key structural motifs accounting for their difference of glass forming ability. Here we adopt ab initio molecular dynamics simulations to investigate the local atomic structures of Zr50Cu45Al5 and Cu50Zr45Al5 MGs. A high content of icosahedral-related (full and distorted) orders was found in both samples, while in the Zr-rich MG full icosahedrons <0,0,12,0> is dominant, and in the Cu-rich one the distorted icosahedral orders, especially <0,2,8,2> and <0,2,8,1>, are prominent. And the <0,2,8,2> polyhedra in Cu50Zr45Al5 MG mainly originate from Al-centeredmore » clusters, while the <0,0,12,0> in Zr50Cu45Al5 derives from both Cu-centered clusters and Al-centered clusters. These difference may be ascribed to the atomic size difference and chemical property between Cu and Zr atoms. The relatively large size of Zr and large negative heat of mixing between Zr and Al atoms, enhancing the packing density and stability of metallic glass system, may be responsible for the higher glass forming ability of Zr50Cu45Al5.« less

  1. Ab initio molecular dynamics simulations of short-range order in Zr50Cu45Al5 and Cu50Zr45Al5 metallic glasses

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

    Huang, Yuxiang; Huang, Li; Wang, C. Z.; Kramer, M. J.; Ho, K. M.

    2016-02-01

    Comparative analysis between Zr-rich Zr50Cu45Al5 and Cu-rich Cu50Zr45Al5 metallic glasses (MGs) is extensively performed to locate the key structural motifs accounting for their difference of glass forming ability. Here we adopt ab initio molecular dynamics simulations to investigate the local atomic structures of Zr50Cu45Al5 and Cu50Zr45Al5 MGs. A high content of icosahedral-related (full and distorted) orders was found in both samples, while in the Zr-rich MG full icosahedrons < 0,0,12,0 > is dominant, and in the Cu-rich one the distorted icosahedral orders, especially < 0,2,8,2 > and < 0,2,8,1 >, are prominent. And the < 0,2,8,2 > polyhedra in Cu50Zr45Al5more » MG mainly originate from Al-centered clusters, while the < 0,0,12,0 > in Zr50Cu45Al5 derives from both Cu-centered clusters and Al-centered clusters. These difference may be ascribed to the atomic size difference and chemical property between Cu and Zr atoms. Lastly, the relatively large size of Zr and large negative heat of mixing between Zr and Al atoms, enhancing the packing density and stability of metallic glass system, may be responsible for the higher glass forming ability of Zr50Cu45Al5.« less

  2. Impact of deformation on the atomic structures and dynamics of a Cu-Zr metallic glass: A molecular dynamics study

    SciTech Connect (OSTI)

    Zhang, Y.; Mendelev, M. I.; Wang, C. Z.; Ott, R.; Zhang, F.; Besser, M. F.; Ho, K. M.; Kramer, M. J.

    2014-11-03

    Despite numerous studies on the atomic structures of Cu-Zr metallic glasses (MGs), their inherent structural ordering, e.g., medium-range order (MRO), remains difficult to describe. Specifically lacking is an understanding of how the MRO responds to deformation and the associated changes in atomic mobility. In this paper, we focus on the impact of deformation on MRO and associated effect on diffusion in a well-relaxed Cu64.5Zr35.5 MG by molecular dynamics simulations. The Cu-Zr MG exhibits a larger elastic limit of 0.035 and a yield stress of 3.5 GPa. The cluster alignment method was employed to characterize the icosahedral short-range order (ISRO) and Bergman-type medium-range order (BMRO) in the models upon loading and unloading. From this analysis, we find the disruption of both ISRO and BMRO occurs as the strain reaches about 0.02, well below the elastic limit. Within the elastic limit, the total fractions of ISRO or BMRO can be fully recovered upon unloading. The diffusivity increases six to eight times in regions undergoing plastic deformation, which is due to the dramatic disruption of the ISRO and BMRO. As a result, by mapping the spatial distributions of the mobile atoms, we demonstrate the increase in atomic mobility is due to the extended regions of disrupted ISRO and more importantly BMRO.

  3. Impact of deformation on the atomic structures and dynamics of a Cu-Zr metallic glass: A molecular dynamics study

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

    Zhang, Y.; Mendelev, M. I.; Wang, C. Z.; Ott, R.; Zhang, F.; Besser, M. F.; Ho, K. M.; Kramer, M. J.

    2014-11-03

    Despite numerous studies on the atomic structures of Cu-Zr metallic glasses (MGs), their inherent structural ordering, e.g., medium-range order (MRO), remains difficult to describe. Specifically lacking is an understanding of how the MRO responds to deformation and the associated changes in atomic mobility. In this paper, we focus on the impact of deformation on MRO and associated effect on diffusion in a well-relaxed Cu64.5Zr35.5 MG by molecular dynamics simulations. The Cu-Zr MG exhibits a larger elastic limit of 0.035 and a yield stress of 3.5 GPa. The cluster alignment method was employed to characterize the icosahedral short-range order (ISRO) andmore » Bergman-type medium-range order (BMRO) in the models upon loading and unloading. From this analysis, we find the disruption of both ISRO and BMRO occurs as the strain reaches about 0.02, well below the elastic limit. Within the elastic limit, the total fractions of ISRO or BMRO can be fully recovered upon unloading. The diffusivity increases six to eight times in regions undergoing plastic deformation, which is due to the dramatic disruption of the ISRO and BMRO. As a result, by mapping the spatial distributions of the mobile atoms, we demonstrate the increase in atomic mobility is due to the extended regions of disrupted ISRO and more importantly BMRO.« less

  4. Domain wall assisted magnetization switching in (111) oriented L1{sub 0} FePt grown on a soft magnetic metallic glass

    SciTech Connect (OSTI)

    Kaushik, Neelam; Sharma, Parmanand; Yubuta, Kunio; Makino, Akihiro; Inoue, Akihisa

    2010-08-16

    We report on growth and magnetic properties of exchange-coupled (111)-L1{sub 0} FePt hard/CoFeTaB soft magnetic metallic glass bilayered structure processed at lower temperature ({approx}400 deg. C). Single phaselike hysteresis loops with tailorable coercivity (<8.2 kOe) in out of plane direction are obtained. The magnetization switching mechanism is identified as domain wall assisted. In views of excellent nanofabrication abilities of metallic glass thin film and the ability to grow preferred oriented L1{sub 0} FePt, the present bilayered structure is very promising for the fabrication of high density bit--patterned magnetic recording media and other spintronic devices.

  5. Effect of hydrothermal condition on the formation of multi-component oxides of Ni-based metallic glass under high temperature water near the critical point

    SciTech Connect (OSTI)

    Kim, J. S.; Lee, M. H.; Kim, S. Y.; Kim, D. H.; Ott, R. T.; Kim, H. G.

    2015-07-15

    The specific feature of multi-component oxides synthesized by hydrothermal process under high temperature (633 K) and highly pressurized water (18.9 MPa) near critical point. Effects of hydrothermal processing duration times 24 hours and 72 hours, respectively, on the oxide formation of the Ni{sub 59}Zr{sub 20}Ti{sub 16}Si{sub 2}Sn{sub 3} metallic glass synthesized by powder metallurgy process were characterized by X-ray diffractometer, differential scanning calorimeter along with the particle size, morphology and crystalline phase of the oxides. The crystallization of the needle-shape NiTiO{sub 3}, ZrTiO{sub 4} and ZrSnO{sub 4} ternary oxide phases observed on the surface of metallic glass at below glass transition temperature and the morphology of oxide phases changed to plate-shape around 2 μm in diameter by the increase processing time. This hydrothermal processing in subcritical water provides accelerated dense metal oxide crystals due to the reaction medium being at higher pressure than conventional oxidation processing.

  6. Effect of hydrothermal condition on the formation of multi-component oxides of Ni-based metallic glass under high temperature water near the critical point

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

    Kim, J. S.; Kim, S. Y.; Kim, D. H.; Ott, R. T.; Kim, H. G.; Lee, M. H.

    2015-07-01

    The specific feature of multi-component oxides synthesized by hydrothermal process under high temperature (633 K) and highly pressurized water (18.9 MPa) near critical point. Effects of hydrothermal processing duration times 24 hours and 72 hours, respectively, on the oxide formation of the Ni59Zr20Ti16Si2Sn3 metallic glass synthesized by powder metallurgy process were characterized by X-ray diffractometer, differential scanning calorimeter along with the particle size, morphology and crystalline phase of the oxides. The crystallization of the needle-shape NiTiO3, ZrTiO4 and ZrSnO4 ternary oxide phases observed on the surface of metallic glass at below glass transition temperature and the morphology of oxide phasesmore » changed to plate-shape around 2 μm in diameter by the increase processing time. This hydrothermal processing in subcritical water provides accelerated dense metal oxide crystals due to the reaction medium being at higher pressure than conventional oxidation processing.« less

  7. Effect of hydrothermal condition on the formation of multi-component oxides of Ni-based metallic glass under high temperature water near the critical point

    SciTech Connect (OSTI)

    Kim, J. S.; Kim, S. Y.; Kim, D. H.; Ott, R. T.; Kim, H. G.; Lee, M. H.

    2015-07-01

    The specific feature of multi-component oxides synthesized by hydrothermal process under high temperature (633 K) and highly pressurized water (18.9 MPa) near critical point. Effects of hydrothermal processing duration times 24 hours and 72 hours, respectively, on the oxide formation of the Ni59Zr20Ti16Si2Sn3 metallic glass synthesized by powder metallurgy process were characterized by X-ray diffractometer, differential scanning calorimeter along with the particle size, morphology and crystalline phase of the oxides. The crystallization of the needle-shape NiTiO3, ZrTiO4 and ZrSnO4 ternary oxide phases observed on the surface of metallic glass at below glass transition temperature and the morphology of oxide phases changed to plate-shape around 2 μm in diameter by the increase processing time. This hydrothermal processing in subcritical water provides accelerated dense metal oxide crystals due to the reaction medium being at higher pressure than conventional oxidation processing.

  8. Thin Wall Iron Castings

    SciTech Connect (OSTI)

    J.F. Cuttino; D.M. Stefanescu; T.S. Piwonka

    2001-10-31

    Results of an investigation made to develop methods of making iron castings having wall thicknesses as small as 2.5 mm in green sand molds are presented. It was found that thin wall ductile and compacted graphite iron castings can be made and have properties consistent with heavier castings. Green sand molding variables that affect casting dimensions were also identified.

  9. Thin sheet casting with electromagnetic pressurization

    DOE Patents [OSTI]

    Walk, Steven R.; Slepian, R. Michael; Nathenson, Richard D.; Williams, Robert S.

    1991-01-01

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

  10. Clean cast steel technology. Final report

    SciTech Connect (OSTI)

    Bates, C.E.; Griffin, J.A.

    1998-06-01

    This report documents the results obtained from the Clean Cast Steel Technology Program financially supported by the DOE Metal Casting Competitiveness Research Program and industry. The primary objective of this program is to develop technology for delivering steel free of oxide macroinclusions to mold cavities. The overall objective is to improve the quality of cast steel by developing and demonstrating the technology for substantially reducing surface and sub-surface oxide inclusions. Two approaches are discussed here. A total of 23 castings were produced by submerge pouring along with sixty conventionally poured castings. The submerged poured castings contained, on average, 96% fewer observable surface inclusions (11.9 vs 0.4) compared to the conventionally poured cast parts. The variation in the population of surface inclusions also decreased by 88% from 5.5 to 0.7. The machinability of the casting was also improved by submerged pouring. The submerge poured castings required fewer cutting tool changes and less operator intervention during machining. Subsequent to these trials, the foundry has decided to purchase more shrouds for continued experimentation on other problem castings where submerge pouring is possible. An examination of melting and pouring practices in four foundries has been carried out. Three of the four foundries showed significant improvement in casting quality by manipulating the melting practice. These melting practice variables can be grouped into two separate categories. The first category is the pouring and filling practice. The second category concerns the concentration of oxidizable elements contained in the steel. Silicon, manganese, and aluminum concentrations were important factors in all four foundries. Clean heats can consistently be produced through improved melting practice and reducing exposure of the steel to atmospheric oxygen during pouring and filling.

  11. PLZT capacitor on glass substrate

    DOE Patents [OSTI]

    Fairchild, M. Ray; Taylor, Ralph S.; Berlin, Carl W.; Wong, Celine W. K.; Ma, Beihai; Balachandran, Uthamalingam

    2016-01-05

    A lead-lanthanum-zirconium-titanate (PLZT) capacitor on a substrate formed of glass. The first metallization layer is deposited on a top side of the substrate to form a first electrode. The dielectric layer of PLZT is deposited over the first metallization layer. The second metallization layer deposited over the dielectric layer to form a second electrode. The glass substrate is advantageous as glass is compatible with an annealing process used to form the capacitor.

  12. PLZT capacitor on glass substrate

    DOE Patents [OSTI]

    Fairchild, Manuel Ray; Taylor, Ralph S.; Berlin, Carl W.; Wong, Celine Wk; Ma, Beihai; Balachandran, Uthamalingam

    2016-03-29

    A lead-lanthanum-zirconium-titanate (PLZT) capacitor on a substrate formed of glass. The first metallization layer is deposited on a top side of the substrate to form a first electrode. The dielectric layer of PLZT is deposited over the first metallization layer. The second metallization layer deposited over the dielectric layer to form a second electrode. The glass substrate is advantageous as glass is compatible with an annealing process used to form the capacitor.

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

    DOE Patents [OSTI]

    Mangels, John A.; Dickie, Ray A.

    1985-01-01

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

  14. Arc Casting Intermetallic Alloy (Materials Preparation Center)

    SciTech Connect (OSTI)

    2010-01-01

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

  15. Effect of pre-oxidation and environmental aging on the seal strength of a novel high-temperature solid oxide fuel cell (SOFC) sealing glass with metallic interconnect

    SciTech Connect (OSTI)

    Chou, Y. S.; Stevenson, Jeffry W.; Singh, Prabhakar

    2008-09-15

    A novel high-temperature alkaline-earth silicate sealing glass was developed for solid oxide fuel cell (SOFC) applications. The glass was used to join two ferritic stainless steel coupons for strength evaluation. The steel coupons were pre-oxidized at elevated temperatures to promote thick oxide layers to simulate long-term exposure conditions. In addition, seals to as-received metal coupons were also tested after aging in oxidizing or reducing environments to simulate the actual SOFC environment. Room temperature tensile testing showed strength degradation when using pre-oxidized coupons, and more extensive degradation after aging in air. Fracture surface and microstructural analysis confirmed that the cause of degradation was formation of SrCrO4 at the outer sealing edges exposed to air.

  16. Glass Stronger than Steel

    DOE R&D Accomplishments [OSTI]

    Yarris, Lynn

    2011-03-28

    A new type of damage-tolerant metallic glass, demonstrating a strength and toughness beyond that of steel or any other known material, has been developed and tested by a collaboration of researchers from Berkeley Lab and Caltech.

  17. Super ionic conductive glass

    DOE Patents [OSTI]

    Susman, S.; Volin, K.J.

    Described is an ionically conducting glass for use as a solid electrolyte in a power or secondary cell containing an alkali metal-containing anode and a cathode separated by an alkali metal ion conducting glass having an ionic transference number of unity and the general formula: A/sub 1 + x/D/sub 2-x/3/Si/sub x/P/sub 3 - x/O/sub 12 - 2x/3/, wherein A is a network modifier for the glass and is an alkali metal of the anode, D is an intermediate for the glass and is selected from the class consisting of Zr, Ti, Ge, Al, Sb, Be, and Zn and X is in the range of from 2.25 to 3.0. Of the alkali metals, Na and Li are preferred and of the intermediate, Zr, Ti and Ge are preferred.

  18. Super ionic conductive glass

    DOE Patents [OSTI]

    Susman, Sherman; Volin, Kenneth J.

    1984-01-01

    An ionically conducting glass for use as a solid electrolyte in a power or secondary cell containing an alkali metal-containing anode and a cathode separated by an alkali metal ion conducting glass having an ionic transference number of unity and the general formula: A.sub.1+x D.sub.2-x/3 Si.sub.x P.sub.3-x O.sub.12-2x/3, wherein A is a network modifier for the glass and is an alkali metal of the anode, D is an intermediate for the glass and is selected from the class consisting of Zr, Ti, Ge, Al, Sb, Be, and Zn and X is in the range of from 2.25 to 3.0. Of the alkali metals, Na and Li are preferred and of the intermediate, Zr, Ti and Ge are preferred.

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

    SciTech Connect (OSTI)

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

    2007-01-01

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

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

    DOE Patents [OSTI]

    Taleyarkhan, R.P.

    1996-12-24

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

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

    DOE Patents [OSTI]

    Taleyarkhan, Rusi P.

    1996-01-01

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

  2. Metal & Alloy Services | The Ames Laboratory

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

    Metal & Alloy Services The MPC specializes in the preparation, purification, and fabrication of high-purity rare earth metals, refractory metals, alkaline earth metals, and alloys in single and polycrystalline forms. Arc Casting. The interior of an arc casting furnace is shown. Arc casting has been employed for many years at ISU and Ames Laboratory, for preparing alloys and inter-metallic compounds for materials research. The molten metal in the center is zirconium, #40 on the periodic

  3. SLIP CASTING METHOD

    DOE Patents [OSTI]

    Allison, A.G.

    1959-09-01

    S>A process is described for preparing a magnesium oxide slip casting slurry which when used in conjunction with standard casting techniques results in a very strong "green" slip casting and a fired piece of very close dimensional tolerance. The process involves aging an aqueous magnestum oxide slurry, having a basic pH value, until it attains a specified critical viscosity at which time a deflocculating agent is added without upsetting the basic pH value.

  4. Process and apparatus for casting multiple silicon wafer articles

    DOE Patents [OSTI]

    Nanis, Leonard

    1992-05-05

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

  5. Method and apparatus for planar drag strip casting

    DOE Patents [OSTI]

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

    1991-11-12

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

  6. Method and apparatus for planar drag strip casting

    DOE Patents [OSTI]

    Powell, John C.; Campbell, Steven L.

    1991-01-01

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

  7. Advanced Pattern Material for Investment Casting Applications

    SciTech Connect (OSTI)

    F. Douglas Neece Neil Chaudhry

    2006-02-08

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

  8. Insulating and metallic spin glass in KxFe2-δ-yNiySe2 (0.06 ≤ y ≤ 1.44 ) single crystals

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

    Ryu, Hyejin; Abeykoon, Milinda; Wang, Kefeng; Lei, Hechang; Lazarevic, N.; Warren, J. B.; Bozin, E. S.; Popovic, Z. V.; Petrovic, C.

    2015-05-04

    We report electron doping effects by Ni in KxFe2-δ-yNiySe₂ (0.06 ≤ y ≤ 1.44) single crystal alloys. A rich ground state phase diagram is observed. Thus, a small amount of Ni (~ 4%) suppressed superconductivity below 1.8 K, inducing insulating spin glass magnetic ground state for higher Ni content. With further Ni substitution, metallic resistivity is restored. For high Ni concentration in the lattice the unit cell symmetry is high symmetry I4/mmm with no phase separation whereas both I4/m + I4/mmm space groups were detected in the phase separated crystals when concentration of Ni < Fe. The absence of superconductivitymore » coincides with the absence of crystalline Fe vacancy order.« less

  9. Understanding the deformation mechanism of individual phases of a ZrTi-based bulk metallic glass matrix composite using in situ diffraction and imaging methods

    SciTech Connect (OSTI)

    Huang, Yongjiang E-mail: yjhuang@hit.edu.cn; Khong, J. C.; Mi, J. E-mail: yjhuang@hit.edu.cn; Connolley, Thomas

    2014-01-20

    The plasticity of a ZrTi-based bulk metallic glass composite consisting of glassy matrix and crystalline dendritic phase was studied in-situ under identical tensile loading conditions using scanning electron microscopy and synchrotron X-ray diffraction. A generic procedure was developed to separate the diffraction information of the crystalline phases away from that of the matrix and to precisely calculate the microscopic strains of the two phases at different macroscopic load steps. In this way, the time-evolved quantitative links between shear bands nucleation/propagation and the corresponding microscopic stress fields around them are established, providing more quantitative understanding on (1) how the shear bands are driven by the local stress field, and (2) the critical stresses required for the shear bands to nucleate in the crystalline phase, propagate through the crystalline/matrix interface, and finally into the matrix.

  10. CENTRIFUGAL CASTING MACHINE

    DOE Patents [OSTI]

    Shuck, A.B.

    1958-04-01

    A device is described that is specifically designed to cast uraniumn fuel rods in a vacuunn, in order to obtain flawless, nonoxidized castings which subsequently require a maximum of machining or wastage of the expensive processed material. A chamber surrounded with heating elements is connected to the molds, and the entire apparatus is housed in an airtight container. A charge of uranium is placed in the chamber, heated, then is allowed to flow into the molds While being rotated. Water circulating through passages in the molds chills the casting to form a fine grained fuel rod in nearly finished form.

  11. CASTING METHOD AND APPARATUS

    DOE Patents [OSTI]

    Gray, C.F.; Thompson, R.H.

    1958-10-01

    An improved apparatus for the melting and casting of uranium is described. A vacuum chamber is positioned over the casting mold and connected thereto, and a rod to pierce the oxide skin of the molten uranium is fitted into the bottom of the melting chamber. The entire apparatus is surrounded by a jacket, and operations are conducted under a vacuum. The improvement in this apparatus lies in the fact that the top of the melting chamber is fitted with a plunger which allows squeezing of the oxide skin to force out any molten uranium remaining after the skin has been broken and the molten charge has been cast.

  12. Spall behavior of cast iron with varying microstructures

    SciTech Connect (OSTI)

    Plume, Gifford; Rousseau, Carl-Ernst

    2014-07-21

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

  13. Method of casting aerogels

    DOE Patents [OSTI]

    Poco, John F.

    1993-01-01

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

  14. Method of casting aerogels

    DOE Patents [OSTI]

    Poco, J.F.

    1993-09-07

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

  15. Dynamic response of Cu4Zr54 metallic glass to high strain rate shock loading: plasticity, spall and atomic-level structures

    SciTech Connect (OSTI)

    Luo, Shengnian; Arman, Bedri; Germann, Timothy C; Cagin, Tahir

    2009-01-01

    We investigate dynamic response of Cu{sub 46}Zr{sub 54} metallic glass under adiabatic planar shock wave loading (one-dimensional strain) wjth molecular dynamics simulations, including Hugoniot (shock) states, shock-induced plasticity and spallation. The Hugoniot states are obtained up to 60 CPa along with the von Mises shear flow strengths, and the dynamic spall strength, at different strain rates and temperatures. The spall strengths likely represent the limiting values achievable in experiments such as laser ablation. For the steady shock states, a clear elastic-plastic transition is identified (e.g., in the shock velocity-particle velocity curve), and the shear strength shows strain-softening. However, the elastic-plastic transition across the shock front displays transient stress overshoot (hardening) above the Hugoniot elastic limit followed by a relatively sluggish relaxation to the steady shock state, and the plastic shock front steepens with increasing shock strength. The local von Mises shear strain analysis is used to characterize local deformation, and the Voronoi tessellation analysis, the corresponding short-range structures at various stages of shock, release, tension and spallation. The plasticity in this glass is manifested as localized shear transformation zones and of local structure rather than thermal origin, and void nucleation occurs preferentially at the highly shear-deformed regions. The Voronoi and shear strain analyses show that the atoms with different local structures are of different shear resistances that lead to shear localization (e.g., the atoms indexed with (0,0,12,0) are most shear-resistant, and those with (0,2,8,1) are highly prone to shear flow). The dynamic changes in local structures are consistent with the observed deformation dynamics.

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

    DOE Patents [OSTI]

    Johnson, Robert Alan; Schaeffer, Jon Conrad; Lee, Ching-Pang; Abuaf, Nesim; Hasz, Wayne Charles

    2002-01-01

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

  17. Optimization of Squeeze Casting for Aluminum Alloy Parts

    SciTech Connect (OSTI)

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

    2002-07-30

    This study was initiated with the installation of a new production size UBE 350 Ton VSC Squeeze Casting system in the Metal Casting Laboratory at Case Western University. A Lindberg 75k W electrical melting furnace was installed alongside. The challenge of installation and operation of such industrial-size equipment in an academic environment was met successfully. Subsequently, a Sterling oil die heater and a Visi-Track shot monitoring system were added. A significant number of inserts were designed and fabricated over the span of the project, primarily for squeeze casting different configurations of test bars and plates. A spiral ''ribbon insert'' for evaluation of molten metal fluidity was also fabricated. These inserts were used to generate a broad range of processing conditions and determine their effect on the quality of the squeeze cast parts. This investigation has studied the influence of the various casting variables on the quality of indirect squeeze castings primarily of aluminum alloys. The variables studied include gating design, fill time and fill patter, metal pressure and die temperature variations. The quality of the die casting was assessed by an analysis of both their surface condition and internal soundness. The primary metal tested was an aluminum 356 alloy. In addition to determining the effect of these casting variables on casting quality as measured by a flat plate die of various thickness, a number of test bar inserts with different gating designs have been inserted in the squeeze casting machine. The mechanical properties of these test bars produced under different squeeze casting conditions were measured and reported. The investigation of the resulting properties also included an analysis of the microstructure of the squeeze castings and the effect of the various structural constituents on the resulting properties. The main conclusions from this investigation are as follows: The ingate size and shape are very important since it must

  18. Activation volume in heterogeneous deformation of Mg{sub 65}Cu{sub 12.5}Ni{sub 12.5}(Ce{sub 75}La{sub 25}){sub 10} metallic glass

    SciTech Connect (OSTI)

    Thurieau, Nicolas; Perrière, Loïc; Laurent-Brocq, Mathilde; Champion, Yannick

    2015-11-28

    Depth variation at constant load in instrumented nano-indentation was used to measure activation volume controlling shear band formation in the Mg{sub 65}Cu{sub 12.5}Ni{sub 12.5}(Ce{sub 75}La{sub 25}){sub 10} metallic glass. A series of measurements revealed a large scattering of the data spanning from 100 Å{sup 3} to 800 Å{sup 3}. The distribution of values, which is not following a normal one, may be attributed to the atomic structure of metallic glasses with the absence of long range order, leading to different volume fraction of shear bands for independent experiments. Activation volume is analyzed considering the variation of shear band volume fraction leading to a unique value of a true activation volume. An interpretation for the distribution of values is proposed.

  19. Secondary Waste Cast Stone Waste Form Qualification Testing Plan

    SciTech Connect (OSTI)

    Westsik, Joseph H.; Serne, R. Jeffrey

    2012-09-26

    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 – 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

  20. 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.

    2013-03-27

    More than 56 million gallons of radioactive and hazardous waste are stored in 177 underground storage tanks at the U.S. Department of Energy’s (DOE’s) 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

  1. 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.; Daniel, Sabah S.; Wood, J. F. Barry

    1990-02-20

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

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

    SciTech Connect (OSTI)

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

    2013-07-01

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

  3. 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.

    1988-10-01

    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.

  4. Extrusion cast explosive

    DOE Patents [OSTI]

    Scribner, Kenneth J.

    1985-01-01

    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.

  5. Pressurized heat treatment of glass ceramic

    DOE Patents [OSTI]

    Kramer, D.P.

    1984-04-19

    A method of producing a glass-ceramic having a specified thermal expansion value is disclosed. The method includes the step of pressurizing the parent glass material to a predetermined pressure during heat treatment so that the glass-ceramic produced has a specified thermal expansion value. Preferably, the glass-ceramic material is isostatically pressed. A method for forming a strong glass-ceramic to metal seal is also disclosed in which the glass-ceramic is fabricated to have a thermal expansion value equal to that of the metal. The determination of the thermal expansion value of a parent glass material placed in a high-temperature environment is also used to determine the pressure in the environment.

  6. Extrusion cast explosive

    DOE Patents [OSTI]

    Scribner, K.J.

    1985-11-26

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

  7. Extrusion cast explosive

    DOE Patents [OSTI]

    Scribner, K.J.

    1985-01-29

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

  8. Glass matrix armor

    DOE Patents [OSTI]

    Calkins, Noel C.

    1991-01-01

    An armor system which utilizes glass. A plurality of constraint cells are mounted on a surface of a substrate, which is metal armor plate or a similar tough material, such that the cells almost completely cover the surface of the substrate. Each constraint cell has a projectile-receiving wall parallel to the substrate surface and has sides which are perpendicular to and surround the perimeter of the receiving wall. The cells are mounted such that, in one embodiment, the substrate surface serves as a sixth side or closure for each cell. Each cell has inside of it a plate, termed the front plate, which is parallel to and in contact with substantially all of the inside surface of the receiving wall. The balance of each cell is completely filled with a projectile-abrading material consisting of glass and a ceramic material and, in certain embodiments, a polymeric material. The glass may be in monolithic form or particles of ceramic may be dispersed in a glass matrix. The ceramic material may be in monolithic form or may be in the form of particles dispersed in glass or dispersed in said polymer.

  9. Enhanced Resonance Inspection for Light Metal Castings

    Broader source: Energy.gov [DOE]

    2010 DOE Vehicle Technologies and Hydrogen Programs Annual Merit Review and Peer Evaluation Meeting, June 7-11, 2010 -- Washington D.C.

  10. Manufacturers Saving with Lost Foam Metal Casting

    Broader source: Energy.gov [DOE]

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

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

    SciTech Connect (OSTI)

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

    2010-03-15

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

  12. LOST FOAM CASTING OF MAGNESIUM ALLOYS

    SciTech Connect (OSTI)

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

    2007-01-01

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

  13. Cast dielectric composite linear accelerator

    DOE Patents [OSTI]

    Sanders, David M.; Sampayan, Stephen; Slenes, Kirk; Stoller, H. M.

    2009-11-10

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

  14. Refractory Glass Seals for SOFC

    SciTech Connect (OSTI)

    Chou, Y. S.; Stevenson, Jeffry W.

    2011-07-01

    One of the critical challenges facing planar solid oxide fuel cell (SOFC) technology is the need for reliable sealing technology. Seals must exhibit long-term stability and mechanical integrity in the high temperature SOFC environment during normal and transient operation. Several different approaches for sealing SOFC stacks are under development, including glass or glass-ceramic seals, metallic brazes, and compressive seals. Among glass seals, rigid glass-ceramics, self-healing glass, and composite glass approaches have been investigated under the SECA Core Technology Program. The U.S. Department of Energy's Pacific Northwest National Laboratory (PNNL) has developed the refractory glass approach in light of the fact that higher sealing temperatures (e.g., 930-1000 degrees C) may enhance the ultimate in-service bulk strength and electrical conductivity of contact materials, as well as the bonding strength between contact materials and adjacent SOFC components, such as interconnect coatings and electrodes. This report summarizes the thermal, chemical, mechanical, and electrical properties of the refractory sealing glass.

  15. Seal welded cast iron nuclear waste container

    DOE Patents [OSTI]

    Filippi, Arthur M.; Sprecace, Richard P.

    1987-01-01

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

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

    SciTech Connect (OSTI)

    Jerald Brevick; R. Allen Miller

    2004-03-15

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

  17. ITP Glass: Glass Industry of the Future: Energy and Environmental...

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

    ITP Glass: Industrial Glass Bandwidth Analysis Final Report, August 2007 ITP Glass: A Clear Vision for a Bright Future ITP Glass: Glass Industry Technology Roadmap; April 2002

  18. Structural transition and orbital glass physics in near-itinerant...

    Office of Scientific and Technical Information (OSTI)

    Title: Structural transition and orbital glass physics in ... which can be driven metallic with moderate applied pressure. ... Type: Accepted Manuscript Journal Name: Physical Review B ...

  19. Large magnetic entropy change and adiabatic temperature rise of a Gd{sub 55}Al{sub 20}Co{sub 20}Ni{sub 5} bulk metallic glass

    SciTech Connect (OSTI)

    Xia, L.; Tang, M. B.; Chan, K. C.; Dong, Y. D.

    2014-06-14

    Gd{sub 55}Al{sub 20}Co{sub 20}Ni{sub 5} bulk metallic glass (BMG) was synthesized by minor Ni substitution for Co in the Gd{sub 55}Al{sub 20}Co{sub 25} BMG in which excellent glass forming ability (GFA) and magneto-caloric effect were reported previously. The Gd{sub 55}Al{sub 20}Ni{sub 20}Co{sub 5} amorphous rod has a similar GFA to the Gd{sub 55}Al{sub 20}Co{sub 25} BMG but exhibits better magnetic properties. The peak value of magnetic entropy change (−ΔS{sub m}{sup peak}) of the Gd{sub 55}Al{sub 20}Co{sub 20}Ni{sub 5} BMG is 9.8 Jkg{sup −1} K{sup −1}. The field dependence of −ΔS{sub m}{sup peak} follows a −ΔS{sub m}{sup peak}∝H{sup 0.85} relationship. The adiabatic temperature rise of the rod is 4.74 K under 5 T and is larger than of other BMGs previously reported. The improved magnetic properties were supposed to be induced by the enhanced interaction between 4f electron in the rare-earth and 3d electron in the transition metal elements by means of a minor Ni substitution for Co.

  20. Directly susceptible, noncarbon metal ceramic composite crucible

    DOE Patents [OSTI]

    Holcombe, Jr., Cressie E.; Kiggans, Jr., James O.; Morrow, S. Marvin; Rexford, Donald

    1999-01-01

    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.

  1. Sealing glasses for titanium and titanium alloys

    DOE Patents [OSTI]

    Brow, Richard K.; Watkins, Randall D.

    1992-01-01

    Glass compositions containing CaO, Al.sub.2 O.sub.3, B.sub.2 O.sub.3, SrO and BaO of various combinations of mole % are provided. These compositions are capable of forming stable glass-to-metal seals with titanium and titanium alloys, for use in components such as seals for battery headers.

  2. Sealing glasses for titanium and titanium alloys

    DOE Patents [OSTI]

    Brow, R.K.; Watkins, R.D.

    1988-01-21

    Glass compositions containing CaO, Al/sub 2/O/sub 3/, B/sub 2/O/sub 3/, SrO and BaO of various combinations of mole % are provided. These compositions are capable of forming stable glass-to-metal seals with titanium and titanium alloys, for use in components such as seals for battery headers.

  3. Glass Ceramic Formulation Data Package

    SciTech Connect (OSTI)

    Crum, Jarrod V.; Rodriguez, Carmen P.; McCloy, John S.; Vienna, John D.; Chung, Chul-Woo

    2012-06-17

    A glass ceramic waste form is being developed for treatment of secondary waste streams generated by aqueous reprocessing of commercial used nuclear fuel (Crum et al. 2012b). The waste stream contains a mixture of transition metals, alkali, alkaline earths, and lanthanides, several of which exceed the solubility limits of a single phase borosilicate glass (Crum et al. 2009; Caurant et al. 2007). A multi-phase glass ceramic waste form allows incorporation of insoluble components of the waste by designed crystallization into durable heat tolerant phases. The glass ceramic formulation and processing targets the formation of the following three stable crystalline phases: (1) powellite (XMoO4) where X can be (Ca, Sr, Ba, and/or Ln), (2) oxyapatite Yx,Z(10-x)Si6O26 where Y is alkaline earth, Z is Ln, and (3) lanthanide borosilicate (Ln5BSi2O13). These three phases incorporate the waste components that are above the solubility limit of a single-phase borosilicate glass. The glass ceramic is designed to be a single phase melt, just like a borosilicate glass, and then crystallize upon slow cooling to form the targeted phases. The slow cooling schedule is based on the centerline cooling profile of a 2 foot diameter canister such as the Hanford High-Level Waste canister. Up to this point, crucible testing has been used for glass ceramic development, with cold crucible induction melter (CCIM) targeted as the ultimate processing technology for the waste form. Idaho National Laboratory (INL) will conduct a scaled CCIM test in FY2012 with a glass ceramic to demonstrate the processing behavior. This Data Package documents the laboratory studies of the glass ceramic composition to support the CCIM test. Pacific Northwest National Laboratory (PNNL) measured melt viscosity, electrical conductivity, and crystallization behavior upon cooling to identify a processing window (temperature range) for melter operation and cooling profiles necessary to crystallize the targeted phases in the

  4. 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.

    2005-09-30

    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

  5. 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.

    2005-09-30

    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

  6. CADMIUM-RARE EARTH BORATE GLASS AS REACTOR CONTROL MATERIAL

    DOE Patents [OSTI]

    Ploetz, G.L.; Ray, W.E.

    1958-11-01

    A reactor control rod fabricated from a cadmiumrare earth-borate glass is presented. The rare earth component of this glass is selected from among those rare earths having large neutron capture cross sections, such as samarium, gadolinium or europium. Partlcles of this glass are then dispersed in a metal matrix by standard powder metallurgy techniques.

  7. Rapid prototyping: A paradigm shift in investment casting

    SciTech Connect (OSTI)

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

    1996-09-01

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

  8. DEVELOPMENT OF GLASS MATRICES FOR HLW RADIOACTIVE WASTES

    SciTech Connect (OSTI)

    Jantzen, C.

    2010-03-18

    Vitrification is currently the most widely used technology for the treatment of high level radioactive wastes (HLW) throughout the world. Most of the nations that have generated HLW are immobilizing in either borosilicate glass or phosphate glass. One of the primary reasons that glass has become the most widely used immobilization media is the relative simplicity of the vitrification process, e.g. melt waste plus glass forming frit additives and cast. A second reason that glass has become widely used for HLW is that the short range order (SRO) and medium range order (MRO) found in glass atomistically bonds the radionuclides and governs the melt properties such as viscosity, resistivity, sulphate solubility. The molecular structure of glass controls contaminant/radionuclide release by establishing the distribution of ion exchange sites, hydrolysis sites, and the access of water to those sites. The molecular structure is flexible and hence accounts for the flexibility of glass formulations to waste variability. Nuclear waste glasses melt between 1050-1150 C which minimizes the volatility of radioactive components such as Tc{sup 99}, Cs{sup 137}, and I{sup 129}. Nuclear waste glasses have good long term stability including irradiation resistance. Process control models based on the molecular structure of glass have been mechanistically derived and have been demonstrated to be accurate enough to control the world's largest HLW Joule heated ceramic melter in the US since 1996 at 95% confidence.

  9. Titanium sealing glasses and seals formed therefrom

    DOE Patents [OSTI]

    Brow, Richard K.; McCollister, Howard L.; Phifer, Carol C.; Day, Delbert E.

    1997-01-01

    Alkaline-earth lanthanoborate sealing-glass compositions containing CaO, La.sub.2 O.sub.3, B.sub.2 O.sub.3, TiO.sub.2 and Al.sub.2 O.sub.3 in various combinations of mole-% are provided. These sealing-glass compositions are useful for forming hermetic glass-to-metal seals with titanium and titanium alloys that have a high aqueous durability for component or device applications requiring exposure to moisture, water or body fluids. Particular applications of the titanium sealing-glass compositions include forming glass-to-metal seals for lithium batteries and implanted biomedical devices (e.g. batteries, pacemakers, defibrillators, pumps).

  10. Titanium sealing glasses and seals formed therefrom

    DOE Patents [OSTI]

    Brow, R.K.; McCollister, H.L.; Phifer, C.C.; Day, D.E.

    1997-12-02

    Alkaline-earth lanthanoborate sealing-glass compositions containing CaO, La{sub 2}O{sub 3}, B{sub 2}O{sub 3}, TiO{sub 2} and Al{sub 2}O{sub 3} in various combinations of mole-% are provided. These sealing-glass compositions are useful for forming hermetic glass-to-metal seals with titanium and titanium alloys that have a high aqueous durability for component or device applications requiring exposure to moisture, water or body fluids. Particular applications of the titanium sealing-glass compositions include forming glass-to-metal seals for lithium batteries and implanted biomedical devices (e.g. batteries, pacemakers, defibrillators, pumps). 2 figs.

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

    SciTech Connect (OSTI)

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

    2000-02-01

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

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

    Broader source: Energy.gov [DOE]

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

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

    Broader source: Energy.gov [DOE]

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

  14. Insulating and metallic spin glass in KxFe2-δ-yNiySe2 (0.06 ≤ y ≤ 1.44 ) single crystals

    SciTech Connect (OSTI)

    Ryu, Hyejin; Abeykoon, Milinda; Wang, Kefeng; Lei, Hechang; Lazarevic, N.; Warren, J. B.; Bozin, E. S.; Popovic, Z. V.; Petrovic, C.

    2015-05-04

    We report electron doping effects by Ni in KxFe2-δ-yNiySe₂ (0.06 ≤ y ≤ 1.44) single crystal alloys. A rich ground state phase diagram is observed. Thus, a small amount of Ni (~ 4%) suppressed superconductivity below 1.8 K, inducing insulating spin glass magnetic ground state for higher Ni content. With further Ni substitution, metallic resistivity is restored. For high Ni concentration in the lattice the unit cell symmetry is high symmetry I4/mmm with no phase separation whereas both I4/m + I4/mmm space groups were detected in the phase separated crystals when concentration of Ni < Fe. The absence of superconductivity coincides with the absence of crystalline Fe vacancy order.

  15. Insulating and metallic spin glass in KxFe2-?-yNiySe2 (0.06 ? y ? 1.44 ) single crystals

    SciTech Connect (OSTI)

    Ryu, Hyejin; Abeykoon, Milinda; Wang, Kefeng; Lei, Hechang; Lazarevic, N.; Warren, J. B.; Bozin, E. S.; Popovic, Z. V.; Petrovic, C.

    2015-05-04

    We report electron doping effects by Ni in KxFe2-?-yNiySe? (0.06 ? y ? 1.44) single crystal alloys. A rich ground state phase diagram is observed. Thus, a small amount of Ni (~ 4%) suppressed superconductivity below 1.8 K, inducing insulating spin glass magnetic ground state for higher Ni content. With further Ni substitution, metallic resistivity is restored. For high Ni concentration in the lattice the unit cell symmetry is high symmetry I4/mmm with no phase separation whereas both I4/m + I4/mmm space groups were detected in the phase separated crystals when concentration of Ni < Fe. The absence of superconductivity coincides with the absence of crystalline Fe vacancy order.

  16. Bio-corrosion and cytotoxicity studies on novel Zr55Co30Ti15 and Cu60Zr20Ti20 metallic glasses

    SciTech Connect (OSTI)

    Vincent, S.; Daiwile, A.; Devi, S. S.; Kramer, M. J.; Besser, M. F.; Murty, B. S.; Bhatt, Jatin

    2014-09-26

    Metallic glasses are a potential and compatible implant candidate for biomedical applications. In the present investigation, a comparative study between novel Zr55Co30Ti15 and Cu60Zr20Ti20 metallic glasses is carried out to evaluate in vitro biocompatibility using simulated body fluids. The bio-corrosion behavior of Zr- and Cu-based metallic glasses in different types of artificial body fluids such as artificial saliva solution, phosphate-buffered saline solution, artificial blood plasma solution, and Hanks balanced saline solution is evaluated using potentiodynamic polarization studies at a constant body temperature of 310.15 K (37 C). Surface morphology of samples after bio-corrosion experiments was observed by scanning electron microscopy. In vitro cytotoxicity test on glassy alloys were performed using human osteosarcoma cell line as per 10993-5 guidelines from International Organization for Standardization. As a result, the comparative study between Zr- and Cu-based glassy alloys provides vital information about the effect of elemental composition on biocompatibility of metallic glasses.

  17. Development of a new casting method to fabricate UZr alloy containing minor actinides

    SciTech Connect (OSTI)

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

    2014-01-01

    Metal fuel slugs of UZr alloys for a sodium-cooled fast reactor (SFR) have conventionally been fabricated using an injection casting method. However, casting alloys containing volatile radioactive constituents, such as Am, are problematic in a conventional injection casting method. As an alternative fabrication method, low pressure gravity casting has been developed. Casting soundness, microstructural characteristics, alloying composition, density, and fuel losses were evaluated for the following as-cast fuel slugs: U10 wt% Zr, U10 wt% Zr5 wt% RE, and U10 wt% Zr5 wt% RE5 wt% Mn. The U and Zr contents were uniform throughout the matrix, and impurities such as oxyen, carbon, and nitrogen satisfied the specification of total impurities less than 2,000 ppm. The appearance of the fuel slugs was generally sound, and the internal integrity was shown to be satisfactory based on gamma-ray radiography. In a volatile surrogate casting test, the UZrREMn fuel slug showed that nearly all of the manganese was retained when casting was done under an inert atmosphere.

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

    SciTech Connect (OSTI)

    Dr. Von L. Richards

    2011-09-30

    This project addresses improvements in metal casting processes by reducing scrap and reducing the cost of production, due to scrap reduction from investment casting and yield improvement offered by lost foam casting as compared to no-bake or green sand molding. The objectives for the investment casting portion of the subtask are to improve knowledge of fracture toughness of mold shells and the sources of strength limiting flaws and to understand the effects of wax reclamation procedures on wax properties. Applying 'clean steel' approaches to pouring technology and cleanliness in investment casting of steel are anticipated to improve incoming materials inspection procedures as they affect the microstructure and toughness of the shell. This project focused on two areas of study in the production of steel castings to reduce scrap and save energy: (1) Reducing the amount of shell cracking in investment cast steel production; (2) Investigate the potential of lost foam steel casting The basic findings regarding investment casting shell cracking were: (1) In the case of post pouring cracking, this could be related to phase changes in silica upon cooling and could be delayed by pouring arrangement strategies that maintained the shell surface at temperature for longer time. Employing this delay resulted in less adherent oxidation of castings since the casting was cooler at the time o fair exposure. (2) A model for heat transfer through water saturated shell materials under steam pressure was developed. (3) Initial modeling result of autoclave de-waxing indicated the higher pressure and temperature in the autoclave would impose a steeper temperature gradient on the wax pattern, causing some melt flow prior to bulk expansion and decreasing the stress on the green shell. Basic findings regarding lost foam casting of steel at atmospheric pressure: (1) EPS foam generally decomposes by the collapse mode in steel casting. (2) There is an accumulation of carbon pick-up at the end

  19. Structure of the glass-forming metallic liquids by ab-initio and classical molecular dynamics, a case study: Quenching the Cu{sub 60}Ti{sub 20}Zr{sub 20} alloy

    SciTech Connect (OSTI)

    Amokrane, S.; Ayadim, A.; Levrel, L.

    2015-11-21

    We consider the question of the amorphization of metallic alloys by melt quenching, as predicted by molecular dynamics simulations with semi-empirical potentials. The parametrization of the potentials is discussed on the example of the ternary Cu-Ti-Zr transition metals alloy, using the ab-initio simulation as a reference. The pair structure in the amorphous state is computed from a potential of the Stillinger-Weber form. The transferability of the parameters during the quench is investigated using two parametrizations: from solid state data, as usual and from a new parametrization on the liquid structure. When the adjustment is made on the pair structure of the liquid, a satisfactory transferability is found between the pure components and their alloys. The liquid structure predicted in this way agrees well with experiment, in contrast with the one obtained using the adjustment on the solid. The final structure, after quenches down to the amorphous state, determined with the new set of parameters is shown to be very close to the ab-initio one, the latter being in excellent agreement with recent X-rays diffraction experiments. The corresponding critical temperature of the glass transition is estimated from the behavior of the heat capacity. Discussion on the consistency between the structures predicted using semi-empirical potentials and ab-initio simulation, and comparison of different experimental data underlines the question of the dependence of the final structure on the thermodynamic path followed to reach the amorphous state.

  20. Tape casting and partial melting of Bi-2212 thick films

    SciTech Connect (OSTI)

    Buhl, D.; Lang, T.; Heeb, B.

    1994-12-31

    To produce Bi-2212 thick films with high critical current densities tape casting and partial melting is a promising fabrication method. Bi-2212 powder and organic additives were mixed into a slurry and tape casted onto glass by the doctor blade tape casting process. The films were cut from the green tape and partially molten on Ag foils during heat treatment. We obtained almost single-phase and well-textured films over the whole thickness of 20 {mu}m. The orientation of the (a,b)-plane of the grains were parallel to the substrate with a misalignment of less than 6{degrees}. At 77K/OT a critical current density of 15`000 A/cm{sup 2} was reached in films of the dimension 1cm x 2cm x 20{mu}m (1{mu}V/cm criterion, resistively measured). At 4K/OT the highest value was 350`000 A/cm{sup 2} (1nV/cm criterion, magnetically measured).

  1. ITP Glass: Industrial Glass Bandwidth Analysis Final Report,...

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

    ITP Glass: Glass Industry of the Future: Energy and Environmental Profile of the U.S. Glass Industry; April, 2002 ITP Glass: Glass Industry Technology Roadmap; April 2002 ITP ...

  2. Tape casting of magnesium oxide.

    SciTech Connect (OSTI)

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

    2008-02-01

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

  3. Alkali-lead-iron phosphate glass and associated method

    DOE Patents [OSTI]

    Boatner, L.A.; Sales, B.C.; Franco, S.C.S.

    1994-03-29

    A glass composition and method of preparation utilizes a mixture consisting of phosphorus oxide within the range of about 40 to 49 molar percent, lead oxide within the range of about 10 to 25 molar percent, iron oxide within the range of about 10 to 17 molar percent and an alkali oxide within the range of about 23 to 30 molar percent. The glass resulting from the melting and subsequent solidifying of the mixture possesses a high degree of durability and a coefficient of thermal expansion as high as that of any of a number of metals. Such features render this glass highly desirable in glass-to-metal seal applications. 6 figures.

  4. Alkali-lead-iron phosphate glass and associated method

    DOE Patents [OSTI]

    Boatner, Lynn A.; Sales, Brian C.; Franco, Sofia C. S.

    1994-01-01

    A glass composition and method of preparation utilizes a mixture consisting of phosphorus oxide within the range of about 40 to 49 molar percent, lead oxide within the range of about 10 to 25 molar percent, iron oxide within the range of about 10 to 17 molar percent and an alkali oxide within the range of about 23 to 30 molar percent. The glass resulting from the melting and subsequent solidifying of the mixture possesses a high degree of durability and a coefficient of thermal expansion as high as that of any of a number of metals. Such features render this glass highly desirable in glass-to-metal seal applications.

  5. High expansion, lithium corrosion resistant sealing glasses

    DOE Patents [OSTI]

    Brow, Richard K.; Watkins, Randall D.

    1991-01-01

    Glass compositions containing CaO, Al.sub.2 O.sub.3, B.sub.2 O.sub.3, SrO and BaO in various combinations of mole % are provided. These compositions are capable of forming stable glass-to-metal seals with pin materials of 446 Stainless Steel and Alloy-52 rather than molybdenum, for use in harsh chemical environments, specifically in lithium batteries.

  6. High expansion, lithium corrosion resistant sealing glasses

    DOE Patents [OSTI]

    Brow, R.K.; Watkins, R.D.

    1991-06-04

    Glass compositions containing CaO, Al[sub 2]O[sub 3], B[sub 2]O[sub 3], SrO and BaO in various combinations of mole % are provided. These compositions are capable of forming stable glass-to-metal seals with pin materials of 446 Stainless Steel and Alloy-52 rather than molybdenum, for use in harsh chemical environments, specifically in lithium batteries.

  7. Nanocrystallization kinetics and glass forming ability of the Fe{sub 65}Nb{sub 10}B{sub 25} metallic alloy

    SciTech Connect (OSTI)

    Torrens-Serra, J.; Rodriguez-Viejo, J.; Clavaguera-Mora, M. T.

    2007-12-01

    The crystallization kinetics of glassy Fe{sub 65}Nb{sub 10}B{sub 25} melt-spun ribbons is studied by differential scanning calorimetry in the mode of continuous heating and isothermal annealing and by x-ray diffraction and transmission electron microscopy. Continuous heat treatments of the ribbons show the presence of multiple exothermic peaks before melting. The low-temperature peak corresponds to the precipitation of nanoscale Fe{sub 23}B{sub 6}-type crystalline metastable phase, and further annealing leads to its transformation into the metastable Fe{sub 3}B phase and subsequent formation of bcc-Fe, Fe{sub 2}B, and FeNbB stable crystalline phases. The nucleation frequency and the growth rate are determined at selected temperatures from the analysis of the microstructures that emerge during the Fe{sub 23}B{sub 6}-type nanocrystallization. The master curve method is used to obtain the apparent activation energy and the Avrami exponent at the nanocrystallization onset. The nanocrystallization kinetics is explained in the framework of the Kolmogorov-Johnson-Mehl-Avrami theory. The rejection of insoluble alloy atoms during primary crystallization, the formation of diffusion layers around the crystals, and the decrease in the nucleation frequency caused by alloy enrichment of the residual disordered matrix is modeled through a soft impingement factor. Estimated values for the interfacial energy that provide a satisfactory agreement between experiments and modeling are derived considering that homogeneous nucleation frequency and interface-controlled grain growth are dominant at the onset of the nanocrystallization. Consequently, the time-temperature-transformation diagram is also drawn and the critical cooling rate estimated for this glass forming alloy.

  8. Process development of thin strip steel casting

    SciTech Connect (OSTI)

    Sussman, R.C.; Williams, R.S.

    1990-12-01

    An important new frontier is being opened in steel processing with the emergence of thin strip casting. Casting steel directly to thin strip has enormous benefits in energy savings by potentially eliminating the need for hot reduction in a hot strip mill. This has been the driving force for numerous current research efforts into the direct strip casting of steel. The US Department of Energy initiated a program to evaluate the development of thin strip casting in the steel industry. In earlier phases of this program, planar flow casting on an experimental caster was studied by a team of engineers from Westinghouse Electric corporation and Armco Inc. A subsequent research program was designed as a fundamental and developmental study of both planar and melt overflow casting processes. This study was arranged as several separate and distinct tasks which were often completed by different teams of researchers. An early task was to design and build a water model to study fluid flow through different designs of planar flow casting nozzles. Another important task was mathematically modeling of melt overflow casting process. A mathematical solidification model for the formation of the strip in the melt overflow process was written. A study of the material and conditioning of casting substrates was made on the small wheel caster using the melt overflow casting process. This report discusses work on the development of thin steel casting.

  9. Prediction of Part Distortion in Die Casting

    SciTech Connect (OSTI)

    R. Allen Miller

    2005-03-30

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

  10. Glass-silicon column

    DOE Patents [OSTI]

    Yu, Conrad M.

    2003-12-30

    A glass-silicon column that can operate in temperature variations between room temperature and about 450.degree. C. The glass-silicon column includes large area glass, such as a thin Corning 7740 boron-silicate glass bonded to a silicon wafer, with an electrode embedded in or mounted on glass of the column, and with a self alignment silicon post/glass hole structure. The glass/silicon components are bonded, for example be anodic bonding. In one embodiment, the column includes two outer layers of silicon each bonded to an inner layer of glass, with an electrode imbedded between the layers of glass, and with at least one self alignment hole and post arrangement. The electrode functions as a column heater, and one glass/silicon component is provided with a number of flow channels adjacent the bonded surfaces.

  11. Fabricated Metals (2010 MECS) | Department of Energy

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

    Fabricated Metals (2010 MECS) Fabricated Metals (2010 MECS) Manufacturing Energy and Carbon Footprint for Fabricated Metals Sector (NAICS 332) Energy use data source: 2010 EIA MECS (with adjustments) Footprint Last Revised: February 2014 View footprints for other sectors here. Manufacturing Energy and Carbon Footprint Fabricated Metals (124.58 KB) More Documents & Publications MECS 2006 - Fabricated Metals Cement (2010 MECS) Glass and Glass Products (2010 MECS) Manufacturing Energy Sankey

  12. Transistors using crystalline silicon devices on glass

    DOE Patents [OSTI]

    McCarthy, Anthony M.

    1995-01-01

    A method for fabricating transistors using single-crystal silicon devices on glass. This method overcomes the potential damage that may be caused to the device during high voltage bonding and employs a metal layer which may be incorporated as part of the transistor. This is accomplished such that when the bonding of the silicon wafer or substrate to the glass substrate is performed, the voltage and current pass through areas where transistors will not be fabricated. After removal of the silicon substrate, further metal may be deposited to form electrical contact or add functionality to the devices. By this method both single and gate-all-around devices may be formed.

  13. ITP Glass: Industrial Glass Bandwidth Analysis Final Report, August 2007 |

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

    Department of Energy Industrial Glass Bandwidth Analysis Final Report, August 2007 ITP Glass: Industrial Glass Bandwidth Analysis Final Report, August 2007 industrial_bandwidth.pdf (360.99 KB) More Documents & Publications ITP Glass: Glass Industry of the Future: Energy and Environmental Profile of the U.S. Glass Industry; April, 2002 ITP Glass: Glass Industry Technology Roadmap; April 2002 ITP Glass: A Clear Vision for a Bright Future

  14. Glass capable of ionic conduction and method of preparation

    DOE Patents [OSTI]

    Susman, Sherman (Park Forest, IL); Boehm, Leah (Jerusalem, IL); Volin, Kenneth J. (Fort Collins, CO); Delbacq, Charles J. (Downers Grove, IL)

    1985-01-01

    Sulfide glasses capable of conducting alkali metal ions are prepared from a nonmetal glass former such as GeS.sub.2, B.sub.2 S.sub.3 and SiS.sub.2 in mixture with a glass modifier such as Na.sub.2 S or another alkali metal sulfide. A molten mixture of the constituents is rapidly quenched to below the glass transition temperature by contact with a metal mold. The rapid quench is sufficient to prevent crystallization and permit solidification as an amorphous solid mixture. An oxygen-free atmosphere is maintained over the mixture to prevent oxidation. A new glass system of (1-X) Na.sub.2 O:XB.sub.2 S.sub.3 is disclosed.

  15. Glass capable of ionic conduction and method of preparation

    DOE Patents [OSTI]

    Susman, Sherman (Park Forest, IL); Delbecq, Charles J. (Downers Grove, IL); Volin, Kenneth J. (Fort Collins, CO); Boehm, Leah (Jerusalem, IL)

    1984-01-01

    Sulfide glasses capable of conducting alkali metal ions are prepared from a nonmetal glass former such as GeS.sub.2, B.sub.2 S.sub.3 and SiS.sub.2 in mixture with a glass modifier such as Na.sub.2 S or another alkali metal sulfide. A molten mixture of the constituents is rapidly quenched to below the glass transition temperature by contact with a metal mold. The rapid quench is sufficient to prevent crystallization and permit solidification as an amorphous solid mixture. An oxygen-free atmosphere is maintained over the mixture to prevent oxidation. A new glass system of (1-X) Na.sub.2 O:XB.sub.2 S.sub.3 is disclosed.

  16. Glass capable of ionic conduction and method of preparation

    DOE Patents [OSTI]

    Susman, S.; Boehm, L.; Volin, K.J.; Delbecq, C.J.

    1982-05-06

    Sulfide glasses capable of conducting alkali metal ions are prepared from a nonmetal glass former such as GeS/sub 2/, B/sub 2/S/sub 2/ and SiS/sub 2/ in mixture with a glass modifier such as Na/sub 2/S or another alkali metal sulfide. A molten mixture of the constituents is rapidly quenched to below the glass transition temperature by contact with a metal mold. The rapid quench is sufficient to prevent crystallization and permit solidification as an amorphous solid mixture. An oxygen-free atmosphere is maintained over the mixture to prevent oxidation. A new glass system of (1 - X) Na/sub 2/O:XB/sub 2/S/sub 3/ is disclosed.

  17. Glass capable of ionic conduction and method of preparation

    DOE Patents [OSTI]

    Susman, S.; Delbecq, C.J.; Volin, K.J.; Boehm, L.

    1984-02-21

    Sulfide glasses capable of conducting alkali metal ions are prepared from a nonmetal glass former such as GeS[sub 2], B[sub 2]S[sub 3] and SiS[sub 2] in mixture with a glass modifier such as Na[sub 2]S or another alkali metal sulfide. A molten mixture of the constituents is rapidly quenched to below the glass transition temperature by contact with a metal mold. The rapid quench is sufficient to prevent crystallization and permit solidification as an amorphous solid mixture. An oxygen-free atmosphere is maintained over the mixture to prevent oxidation. A new glass system of (1-X) Na[sub 2]O:XB[sub 2]S[sub 3] is disclosed. 4 figs.

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

    SciTech Connect (OSTI)

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

    1998-07-01

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

  19. GlassForm

    Energy Science and Technology Software Center (OSTI)

    2011-09-16

    GlassForm is a software tool for generating preliminary waste glass formulas for a given waste stream. The software is useful because it reduces the number of verification melts required to develop a suitable additive composition. The software includes property models that calculate glass properties of interest from the chemical composition of the waste glass. The software includes property models for glass viscosity, electrical conductivity, glass transition temperature, and leach resistance as measured by the 7-daymore » product consistency test (PCT).« less

  20. Method of processing ``BPS`` glass ceramic and seals made therewith

    DOE Patents [OSTI]

    Reed, S.T.; Stone, R.G.; McCollister, H.L.; Wengert, P.R.

    1998-10-13

    A glass ceramic composition, a glass ceramic-to-metal seal, and more specifically a hermetic glass ceramic-to-metal seal prepared by subjecting a glass composition comprising, by weight percent, SiO{sub 2} (65--80%), LiO{sub 2} (8--16%), Al{sub 2}O{sub 3} (2--8%), K{sub 2}O (1--8%), P{sub 2}O{sub 5} (1--5%), B{sub 2}O{sub 3} (0.5--7%), and ZnO (0--5%) to the following processing steps: (1) heating the glass composition in a belt furnace to a temperature sufficient to melt the glass and crystallize lithium phosphate, (2) holding at a temperature and for a time sufficient to create cristobalite nuclei, (3) cooling at a controlled rate and to a temperature to cause crystallization of lithium silicates and growth of cristobalite, and (4) still further cooling in stages to ambient temperature. This process produces a glass ceramic whose high coefficient of thermal expansion (up to 200{times}10{sup {minus}7} in/in/C) permits the fabrication of glass ceramic-to-metal seals, and particularly hermetic glass ceramic seals to nickel-based and stainless steel alloys and copper. 5 figs.

  1. Method of processing "BPS" glass ceramic and seals made therewith

    DOE Patents [OSTI]

    Reed, Scott T.; Stone, Ronald G.; McCollister, Howard L.; Wengert, deceased, Paul R.

    1998-01-01

    A glass ceramic composition, a glass ceramic-to-metal seal, and more specifically a hermetic glass ceramic-to-metal seal prepared by subjecting a glass composition comprising, by weight percent, SiO.sub.2 (65-80%), LiO.sub.2 (8-16%), Al.sub.2 O.sub.3 (2-8%), K.sub.2 O (1-8%), P.sub.2 O.sub.5 (1-5%), B.sub.2 O.sub.3 (0.5-7%), and ZnO (0-5%) to the following processing steps: 1) heating the glass composition in a belt furnace to a temperature sufficient to melt the glass and crystallize lithium phosphate, 2) holding at a temperature and for a time sufficient to create cristobalite nuclei, 3) cooling at a controlled rate and to a temperature to cause crystallization of lithium silicates and growth of cristobalite, and 4) still further cooling in stages to ambient temperature. This process produces a glass ceramic whose high coefficient of thermal expansion (up to 200.times.10.sup.-7 in/in/.degree.C.) permits the fabrication of glass ceramic-to-metal seals, and particularly hermetic glass ceramic seals to nickel-based and stainless steel alloys and copper.

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

    SciTech Connect (OSTI)

    Kuyucak, Selcuk; Li, Delin

    2013-12-31

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

  3. A Benchmark Study on Casting Residual Stress

    SciTech Connect (OSTI)

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

    2012-01-01

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

  4. Low-head feeding system for thin section castings

    DOE Patents [OSTI]

    Daniel, Sabah S.; Kleeb, Thomas R.; Lewis, Thomas W.; McDermott, John F.; Ozgu, Mustafa R.; Padfield, Ralph C.; Rego, Donovan N.; Vassilicos, Achilles

    1990-01-01

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

  5. Glass/ceramic coatings for implants

    DOE Patents [OSTI]

    Tomsia, Antoni P.; Saiz, Eduardo; Gomez-Vega, Jose M.; Marshall, Sally J.; Marshall, Grayson W.

    2011-09-06

    Glass coatings on metals including Ti, Ti6A14V and CrCo were prepared for use as implants. The composition of the glasses was tailored to match the thermal expansion of the substrate metal. By controlling the firing atmosphere, time, and temperature, it was possible to control the reactivity between the glass and the alloy and to fabricate coatings (25-150 .mu.m thick) with excellent adhesion to the substrate. The optimum firing temperatures ranged between 800 and 840.degree. C. at times up to 1 min in air or 15 min in N.sub.2. The same basic technique was used to create multilayered coatings with concentration gradients of hydroxyapatite (HA) particles and SiO.sub.2.

  6. MECS 2006- Glass

    Office of Energy Efficiency and Renewable Energy (EERE)

    Manufacturing Energy and Carbon Footprint for Glass (NAICS 3272, 327993) Sector with Total Energy Input, October 2012 (MECS 2006)

  7. Silica-alumina trihydrate filled epoxy castings resistant to arced SF.sub.6

    DOE Patents [OSTI]

    Chenoweth, Terrence E.; Yeoman, Frederick A.

    1978-01-01

    A cured, insulating, casting composition, having a coefficient of linear thermal expansion of below about 38 .times. 10.sup.-6 in./in./.degree. C and being resistant to arced sulfur hexafluoride gas, in contact with a metal surface in a sulfur hexafluoride gas environment, is made from hydantoin epoxy resin, anhydride curing agent and a filler combination of fused silica and alumina trihydrate.

  8. Industries & Technologies | Department of Energy

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

    Aluminum Chemicals Forest Products Glass Metal Casting Mining Other Industries Petroleum ... Information & Communications Technology Data Centers Materials for Industrial Use ...

  9. Milling of Sand Blocks to Make Casting Moulds

    SciTech Connect (OSTI)

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

    2011-01-17

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

  10. In-situ conditioning of a strip casting roll

    DOE Patents [OSTI]

    Williams, Robert S.; Campbell, Steven L.

    1997-01-01

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

  11. In-situ conditioning of a strip casting roll

    DOE Patents [OSTI]

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

    1997-07-29

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

  12. Commercialization effort in support of electroslag-casting technology

    SciTech Connect (OSTI)

    Sikka, V.K.

    1993-06-01

    This report summarizes the results of an effort to revive interest in the electroslag casting (ESC) of components in the United States. The ESC process is an extension of a well established electroslag-remelting (ESR) process. Both processes use the electrode of a material that is continuously melted and cast in a water-cooled copper mold. For simple shapes, the mold can be movable, allowing the continuous casting of long lengths. In an effort to revive US industries` interest in ESC, the following approaches were taken: (1) US industries with prior experience in ESC or currently operating an ESR unit were contacted, followed up with telephone conversation, and/or sent copies of prior published reports on the topic, and, in some cases, personal visits were made; (2) with two companies, a potential interest in ESC was worked out by initially conducting ESR; and (3) to further strengthen the industrial interest, the newly developed iron-aluminide alloy, FA-129, was chosen as the material of choice for this study. The two industrial companies that worked with ORNL were Special Metals Corporation (New Hartford, New York) and Precision Rolled Products, Inc. (PRP) [Florham Park, New Jersey]. Even with its advantages, a survey of the industry indicated that ESC technology has a very limited chance of advancement in the United States. However, the processing of rounds and slabs by the ESR process is a well established commercial technology and will continue to expand. 16 figs, 3 tabs, 12 refs.

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

    SciTech Connect (OSTI)

    Nagaswaran, R.; Limaye, S.Y.

    1996-02-01

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

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

    SciTech Connect (OSTI)

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

    1996-09-01

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

  15. Yield Improvement in Steel Casting (Yield II)

    SciTech Connect (OSTI)

    Richard A. Hardin; Christoph Beckermann; Tim Hays

    2002-02-18

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

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

    SciTech Connect (OSTI)

    Montgomery, L.C.

    1993-08-24

    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.

  17. Radiation coloration resistant glass

    DOE Patents [OSTI]

    Tomozawa, M.; Watson, E.B.; Acocella, J.

    1986-11-04

    A radiation coloration resistant glass is disclosed which is used in a radiation environment sufficient to cause coloration in most forms of glass. The coloration resistant glass includes higher proportions by weight of water and has been found to be extremely resistant to color change when exposed to such radiation levels. The coloration resistant glass is free of cerium oxide and has more than about 0.5% by weight water content. Even when exposed to gamma radiation of more than 10[sup 7] rad, the coloration resistant glass does not lose transparency. 3 figs.

  18. Radiation coloration resistant glass

    DOE Patents [OSTI]

    Tomozawa, Minoru; Watson, E. Bruce; Acocella, John

    1986-01-01

    A radiation coloration resistant glass is disclosed which is used in a radiation environment sufficient to cause coloration in most forms of glass. The coloration resistant glass includes higher proportions by weight of water and has been found to be extremely resistant to color change when exposed to such radiation levels. The coloration resistant glass is free of cerium oxide and has more than about 0.5% by weight water content. Even when exposed to gamma radiation of more than 10.sup.7 rad, the coloration resistant glass does not lose transparency.

  19. Oxynitride glass production procedure

    DOE Patents [OSTI]

    Weidner, Jerry R. (Idaho Falls, ID); Schuetz, Stanley T. (Idaho Falls, ID); O'Brien, Michael H. (Idaho Falls, ID)

    1991-01-01

    The invention is a process for the preparation of high quality oxynitride glasses without resorting to high pressures. Nitrogen-containing compounds such as Si.sub.3 N.sub.4 are first encapsulated in a low melting temperature glass. Particles of the encapsulated nitrogen-containing compound are mixed with other oxide glass-formers and melted in an atmosphere of flowing nitrogen and in the presence of buffering gas to form the oxynitride glass. Glasses containing up to 15 at % nitrogen have been prepared by this method.

  20. PRODUCTION OF SLIP CAST CALCIA HOLLOWWARE

    DOE Patents [OSTI]

    Stoddard, S.D.; Nuckolls, D.E.; Cowan, R.E.

    1963-12-31

    A method for producing slip cast calcia hollow ware in which a dense calcia grain is suspended in isobutyl acetate or a mixture of tertiary amyl alcohol and o-xylene is presented. A minor amount of triethanolamine and oleic acid is added to the suspension vehicle as viscosity adjusting agents and the suspension is cast in a plaster mold, dried, and fired. (AEC)

  1. Manufacturing Advanced Engineered Components Using Lost Foam Casting Technology

    SciTech Connect (OSTI)

    None

    2004-11-01

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

  2. Enhancements in Magnesium Die Casting Impact Properties (Technical...

    Office of Scientific and Technical Information (OSTI)

    ... Further improvement in impact resistance depends on the processing condition of the casting. Sound castings without porosity and impurities will have better mechanical properties. ...

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

    SciTech Connect (OSTI)

    Beckermann, Christoph; Carlson, Kent

    2011-07-22

    the Navy-C ring (a classical test shape for heat treatment experiments) for several carbon and low alloy steels in order to generate data necessary to validate the code. The predicted distortions were in reasonable agreement with the experimentally measured values. However, the final distortions in the castings were small, making it difficult to determine how accurate the predictions truly are. It is recommended that further validation of the software be performed with the aid of additional experiments with large production steel castings that experience significant heat treatment distortions. It is apparent from this research that the mechanical properties of the bonded sand used for cores and sand molds are key in producing accurate stress simulation results. Because of this, experiments were performed to determine the temperature-dependent elastic modulus of a resin-bonded sand commonly utilized in the steel casting industry. The elastic modulus was seen to vary significantly with heating and cooling rates. Also, the retained room temperature elastic modulus after heating was seen to degrade significantly when the sand was heated above 125°C. The elastic modulus curves developed in this work can readily be utilized in casting simulation software. Additional experiments with higher heating rates are recommended to determine the behavior of the elastic modulus in the sand close to the mold-metal interface. The commercial heat treatment residual stress and distortion code, once fully validated, is expected to result in an estimated energy savings of 2.15 trillion BTU's/year. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology.

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

    DOE Patents [OSTI]

    Follstaedt, Donald W.; King, Edward L.; Schneider, Ken C.

    1991-11-12

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

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

    DOE Patents [OSTI]

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

    1991-11-12

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

  6. Characterization of Technetium Speciation in Cast Stone

    SciTech Connect (OSTI)

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

    2013-11-11

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

  7. Diamond turning of glass

    SciTech Connect (OSTI)

    Blackley, W.S.; Scattergood, R.O.

    1988-12-01

    A new research initiative will be undertaken to investigate the critical cutting depth concepts for single point diamond turning of brittle, amorphous materials. Inorganic glasses and a brittle, thermoset polymer (organic glass) are the principal candidate materials. Interrupted cutting tests similar to those done in earlier research are Ge and Si crystals will be made to obtain critical depth values as a function of machining parameters. The results will provide systematic data with which to assess machining performance on glasses and amorphous materials

  8. Conversion of shale and slate wastes to glass and glass-ceramic products. Open file report 20 Oct 76-19 Sep 79

    SciTech Connect (OSTI)

    MacKenzie, J.D.

    1980-10-20

    Experiments were conducted to convert spent oil shale, waste slate, and copper slag into glass and glass-ceramic products. Spent oil shale was easily melted at 1,300C and converted into glass wool for insulation application. Glass-ceramics were prepared by the use of domestic chrome ore as a nucleating agent. Waste slate from Vermont was readily melted when mixed with limestone. The resultant glass fibers were highly resistant to alkali attack. Iron metal was recovered from copper slags by the use of coal powder as a reducing agent in the molten slag. The lowering of the iron content resulted ina melt that was glass-forming. Combinations of spent oil shale and copper slag also yielded useful glass and glass ceramic compositions.

  9. HLW Glass Waste Loadings

    Office of Environmental Management (EM)

    HLW Glass Waste Loadings Ian L. Pegg Vitreous State Laboratory The Catholic University of ... (JHCM) technology Factors affecting waste loadings Waste loading requirements ...

  10. ITP Glass: Glass Industry Technology Roadmap; April 2002

    Broader source: Energy.gov [DOE]

    Glass is a unique material that has been produced for thousands of years. The glass industry's products are an integral part of the American economy and everyday life. Glass products are used in food and beverage packaging, lighting, communications, etc.

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

    SciTech Connect (OSTI)

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

    2012-07-01

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

  12. Roll Casting of Aluminum Alloy Clad Strip

    SciTech Connect (OSTI)

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

    2011-01-17

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

  13. H-Series Cast Austenitic Stainless Steels

    Broader source: Energy.gov [DOE]

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

  14. Advanced lost foam from casting technology

    SciTech Connect (OSTI)

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

    1996-05-01

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

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

    DOE Patents [OSTI]

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

    1990-12-04

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

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

    DOE Patents [OSTI]

    Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.; Battles, James E.; Hull, John R.; Rote, Donald M.

    1990-01-01

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

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

    DOE Patents [OSTI]

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

    1988-06-17

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

  18. ITP Glass: Glass Industry of the Future: Energy and Environmental...

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

    ... Glass plants remove air pollutants through the use of aqueous media, filters, and precipitators. Air pollution control technologies used in the glass industry commonly transfer ...

  19. Pressurized heat treatment of glass-ceramic to control thermal expansion

    DOE Patents [OSTI]

    Kramer, Daniel P.

    1985-01-01

    A method of producing a glass-ceramic having a specified thermal expansion value is disclosed. The method includes the step of pressurizing the parent glass material to a predetermined pressure during heat treatment so that the glass-ceramic produced has a specified thermal expansion value. Preferably, the glass-ceramic material is isostatically pressed. A method for forming a strong glass-ceramic to metal seal is also disclosed in which the glass-ceramic is fabricated to have a thermal expansion value equal to that of the metal. The determination of the thermal expansion value of a parent glass material placed in a high-temperature environment is also used to determine the pressure in the environment.

  20. Molten metal injector system and method

    DOE Patents [OSTI]

    Meyer, Thomas N.; Kinosz, Michael J.; Bigler, Nicolas; Arnaud, Guy

    2003-04-01

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

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

    SciTech Connect (OSTI)

    David Schwam

    2012-12-15

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

  2. Supplemental Immobilization of Hanford Low-Activity Waste: Cast Stone Screening Tests

    SciTech Connect (OSTI)

    Westsik, Joseph H.; Piepel, Gregory F.; Lindberg, Michael J.; Heasler, Patrick G.; Mercier, Theresa M.; Russell, Renee L.; Cozzi, Alex; Daniel, William E.; Eibling, Russell E.; Hansen, E. K.; Reigel, Marissa M.; Swanberg, David J.

    2013-09-30

    More than 56 million gallons of radioactive and hazardous waste are stored in 177 underground storage tanks at the U.S. Department of Energy’s (DOE’s) 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 LAW immobilization facility will be needed for the expected volume of 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 the waste acceptance criteria for the 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 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

  3. Versa Glass | Open Energy Information

    Open Energy Info (EERE)

    search Name: Versa Glass Place: Columbus, Ohio Zip: 43220 Product: Versa is manufacturing a new technology privacy glass in Ohio that is LEED and has cleantech properties...

  4. Reliability Tools for Resonance Inspection of Light Metal Castings |

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

    NEWS MEDIA CONTACT (202) 586-4940 Washington - Today, U.S. Energy Secretary Steven Chu announced that registration is now open for the 2013 National Science Bowl (NSB). This marks the beginning of the 23rd year of the nation's largest science competition, which is sponsored by the Department of Energy's (DOE's) Office of Science. Local middle school and high school students form teams that compete in regional competitions. The winning teams from the regional competitions then advance to the

  5. ITP Metal Casting: Corrosion Testing Practices … High Alloy...

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

    Various ASTM documents describe laboratory test methods for determining the relative pitting, crevice, and intergranular corrosion resistance of engineering alloys. These test ...

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

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

    12 DOE Hydrogen and Fuel Cells Program and Vehicle Technologies Program Annual Merit Review and Peer Evaluation Meeting PDF icon lm050jones2012o.pdf More Documents & ...

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

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

    ... The cluster is dipped in a refractory slurry and allowed to dry before being introduced ... 11.2 55,328 2.7 Booster Pump 7.2 35,568 1.7 Scrubber Pump - East 16.7 82,498 4.0 Mist Elm. ...

  8. Transistors using crystalline silicon devices on glass

    DOE Patents [OSTI]

    McCarthy, A.M.

    1995-05-09

    A method is disclosed for fabricating transistors using single-crystal silicon devices on glass. This method overcomes the potential damage that may be caused to the device during high voltage bonding and employs a metal layer which may be incorporated as part of the transistor. This is accomplished such that when the bonding of the silicon wafer or substrate to the glass substrate is performed, the voltage and current pass through areas where transistors will not be fabricated. After removal of the silicon substrate, further metal may be deposited to form electrical contact or add functionality to the devices. By this method both single and gate-all-around devices may be formed. 13 figs.

  9. Sealing glasses for titanium and titanium alloys

    DOE Patents [OSTI]

    Brow, R.K.; McCollister, H.L.; Phifer, C.C.; Day, D.E.

    1997-07-15

    Barium lanthanoborate sealing-glass compositions are provided comprising various combinations (in terms of mole-%) of boron oxide (B{sub 2}O{sub 3}), barium oxide (BaO), lanthanum oxide (La{sub 2}O{sub 3}), and at least one other oxide selected from the group consisting of aluminum oxide (Al{sub 2}O{sub 3}), calcium oxide (CaO), lithium oxide (Li{sub 2}O), sodium oxide (Na{sub 2}O), silicon dioxide (SiO{sub 2}), or titanium dioxide (TiO{sub 2}). These sealing-glass compositions are useful for forming hermetic glass-to-metal seals with titanium and titanium alloys having an improved aqueous durability and favorable sealing characteristics. Examples of the sealing-glass compositions are provided having coefficients of thermal expansion about that of titanium or titanium alloys, and with sealing temperatures less than about 900 C, and generally about 700--800 C. The barium lanthanoborate sealing-glass compositions are useful for components and devices requiring prolonged exposure to moisture or water, and for implanted biomedical devices (e.g. batteries, pacemakers, defibrillators, pumps). 1 fig.

  10. Sealing glasses for titanium and titanium alloys

    DOE Patents [OSTI]

    Brow, Richard K.; McCollister, Howard L.; Phifer, Carol C.; Day, Delbert E.

    1997-01-01

    Barium lanthanoborate sealing-glass compositions are provided comprising various combinations (in terms of mole-%) of boron oxide (B.sub.2 O.sub.3), barium oxide (BaO), lanthanum oxide (La.sub.2 O.sub.3), and at least one other oxide selected from the group consisting of aluminum oxide (Al.sub.2 O.sub.3), calcium oxide (CaO), lithium oxide (Li.sub.2 O), sodium oxide (Na.sub.2 O), silicon dioxide (SiO.sub.2), or titanium dioxide (TiO.sub.2). These sealing-glass compositions are useful for forming hermetic glass-to-metal seals with titanium and titanium alloys having an improved aqueous durability and favorable sealing characteristics. Examples of the sealing-glass compositions are provided having coefficients of thermal expansion about that of titanium or titanium alloys, and with sealing temperatures less than about 900.degree. C., and generally about 700.degree.-800.degree. C. The barium lanthanoborate sealing-glass compositions are useful for components and devices requiring prolonged exposure to moisture or water, and for implanted biomedical devices (e.g. batteries, pacemakers, defibrillators, pumps).

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

    DOE Patents [OSTI]

    Praeg, W.F.

    1995-01-31

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

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

    DOE Patents [OSTI]

    Pareg, Walter F.

    1990-01-01

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

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

    DOE Patents [OSTI]

    Praeg, Walter F.

    1995-01-01

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

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

    SciTech Connect (OSTI)

    Das, S.K.; Ningileri, S.; Long, Z.; Saito, K.; Khraisheh, M.; Hassan, M.H.; Kuwana, K.; Han, Q.; Viswanathan, S.; Sabau, A.S.; Clark, J.; Hyrn, J. (ANL)

    2006-08-15

    Approximately 68% of the aluminum produced in the United States is first cast into ingots prior to further processing into sheet, plate, extrusions, or foil. The direct chill (DC) semi-continuous casting process has been the mainstay of the aluminum industry for the production of ingots due largely to its robust nature and relative simplicity. Though the basic process of DC casting is in principle straightforward, the interaction of process parameters with heat extraction, microstructural evolution, and development of solidification stresses is too complex to analyze by intuition or practical experience. One issue in DC casting is the formation of stress cracks [1-15]. In particular, the move toward larger ingot cross-sections, the use of higher casting speeds, and an ever-increasing array of mold technologies have increased industry efficiencies but have made it more difficult to predict the occurrence of stress crack defects. The Aluminum Industry Technology Roadmap [16] has recognized the challenges inherent in the DC casting process and the control of stress cracks and selected the development of 'fundamental information on solidification of alloys to predict microstructure, surface properties, and stresses and strains' as a high-priority research need, and the 'lack of understanding of mechanisms of cracking as a function of alloy' and 'insufficient understanding of the aluminum solidification process', which is 'difficult to model', as technology barriers in aluminum casting processes. The goal of this Aluminum Industry of the Future (IOF) project was to assist the aluminum industry in reducing the incidence of stress cracks from the current level of 5% to 2%. Decreasing stress crack incidence is important for improving product quality and consistency as well as for saving resources and energy, since considerable amounts of cast metal could be saved by eliminating ingot cracking, by reducing the scalping thickness of the ingot before rolling, and by

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

    DOE Patents [OSTI]

    Stoddard, Nathan G

    2014-01-14

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

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

    DOE Patents [OSTI]

    Stoddard, Nathan G.

    2011-11-01

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

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

    SciTech Connect (OSTI)

    Sabau, Adrian S

    2005-09-01

    The investment casting process allows the production of complex-shape parts and close dimensional tolerances. One of the most important phases in the investment casting process is the design of the pattern die. Pattern dies are used to create wax patterns by injecting wax into dies. The wax patterns are used to create a ceramic shell by the application of a series of ceramic coatings, and the alloy is cast into the dewaxed shell mold (Fig. 1.1). However, the complexity of shape and the close dimensional tolerances required in the final casting make it difficult to determine tooling dimensions. The final linear dimension of the casting depends on the cumulative effects of the linear expansions or contractions in each step of the investment casting process (Fig. 1.2). In most cases, the mold geometry or cores restrict the shrinkage of the pattern or the cast part, and the final casting dimensions may be affected by time-dependent processes such as viscoelastic deformation of the wax, and viscoplastic creep and plastic deformations of the shell and alloy. The pattern die is often reworked several times to produce castings whose dimensions are within acceptable tolerances. To date, investment casting technology has been based on hands-on training and experience. Technical literature is limited to experimental, phenomenological studies aimed at obtaining empirical correlations for quick and easy application in industry. The goal of this project was to predict casting dimensions for investment castings in order to meet blueprint nominal during the first casting run. Several interactions have to be considered in a coupled manner to determine the shrinkage factors: these are the die-wax, wax-shell, and shell-alloy interactions (as illustrated in Fig. 1.3). In this work, the deformations of the die-wax and shell-alloy systems were considered in a coupled manner, while the coupled deformation of the wax-shell system was not considered. Future work is needed in order to

  18. Glass electrolyte composition

    DOE Patents [OSTI]

    Kucera, Gene H.; Roche, Michael F.

    1985-01-01

    An ionically conductive glass is disclosed for use as electrolyte in a high temperature electrochemical cell, particularly a cell with sodium anode and sulfur cathode. The glass includes the constituents Na.sub.2 O, ZrO.sub.2, Al.sub.2 O.sub.3 and SiO.sub.2 in selected proportions to be a single phase solid solution substantially free of crystalline regions and undissolved constituents. Other advantageous properties are an ionic conductivity in excess of 2.times.10.sup.-3 (ohm-cm).sup.-1 at 300.degree. C. and a glass transition temperature in excess of 500.degree. C.

  19. Glass electrolyte composition

    DOE Patents [OSTI]

    Kucera, G.H.; Roche, M.F.

    1985-01-08

    An ionically conductive glass is disclosed for use as electrolyte in a high temperature electrochemical cell, particularly a cell with sodium anode and sulfur cathode. The glass includes the constituents Na/sub 2/O, ZrO/sub 2/, Al/sub 2/O/sub 3/ and SiO/sub 2/ in selected proportions to be a single phase solid solution substantially free of crystalline regions and undissolved constituents. Other advantageous properties are an ionic conductivity in excess of 2 x 10/sup -3/ (ohm-cm)/sup -1/ at 300/sup 0/C and a glass transition temperature in excess of 500/sup 0/C.

  20. Glass former composition and method for immobilizing nuclear waste using the same

    DOE Patents [OSTI]

    Cadoff, Laurence H.; Smith-Magowan, David B.

    1988-01-01

    An alkoxide glass former composition has silica-containing constituents present as solid particulates of a particle size of 0.1 to 0.7 micrometers in diameter in a liquid carrier phase substantially free of dissolved silica. The glass former slurry is resistant to coagulation and may contain other glass former metal constituents. The immobilization of nuclear waste employs the described glass former by heating the same to reduce the volume, mixing the same with the waste, and melting the resultant mixture to encapsulate the waste in the resultant glass.

  1. Separate effects identification via casting process modeling for experimental measurement of UPuZr alloys

    SciTech Connect (OSTI)

    J. Crapps; D. S. DeCroix; J. D. Galloway; D. A. Korzekwa; R. Aikin; R. Fielding; R. Kennedy; C. Unal

    2013-11-01

    Computational simulations of gravity casting processes for metallic UPuZr nuclear fuel rods have been performed using a design-of-experiments technique to determine the fluid flow, liquid heat transfer, and solid heat transfer parameters which most strongly influence the process solidification speed and fuel rod porosity. The results are used to make recommendations for the best investment of experimental time and effort to measure process parameters.

  2. Method of bonding metals to ceramics

    DOE Patents [OSTI]

    Maroni, Victor A.

    1991-01-01

    A ceramic or glass having a thin layer of silver, gold or alloys thereof at the surface thereof. A first metal is bonded to the thin layer and a second metal is bonded to the first metal. The first metal is selected from the class consisting of In, Ga, Sn, Bi, Zn, Cd, Pb, Tl and alloys thereof, and the second metal is selected from the class consisting of Cu, Al, Pb, An and alloys thereof.

  3. Method of bonding metals to ceramics

    DOE Patents [OSTI]

    Maroni, V.A.

    1991-04-23

    A ceramic or glass having a thin layer of silver, gold or alloys thereof at the surface thereof is disclosed. A first metal is bonded to the thin layer and a second metal is bonded to the first metal. The first metal is selected from the class consisting of In, Ga, Sn, Bi, Zn, Cd, Pb, Tl and alloys thereof, and the second metal is selected from the class consisting of Cu, Al, Pb, Au and alloys thereof. 3 figures.

  4. Method for making glass nonfogging

    DOE Patents [OSTI]

    Lord, David E.; Carter, Gary W.; Petrini, Richard R.

    1979-01-01

    A method for rendering glass nonfogging (to condensation fog) by sandwiching the glass between two electrodes such that the glass functions as the dielectric of a capacitor, a large alternating current (AC) voltage is applied across the electrodes for a selected time period causing the glass to absorb a charge, and the electrodes are removed. The glass absorbs a charge from the electrodes rendering it nonfogging. The glass surface is undamaged by application of the AC voltage, and normal optical properties are unaffected. This method can be applied to optical surfaces such as lenses, auto windshields, mirrors, etc., wherever condensation fog on glass is a problem.

  5. Baseline LAW Glass Formulation Testing

    SciTech Connect (OSTI)

    Kruger, Albert A.; Mooers, Cavin; Bazemore, Gina; Pegg, Ian L.; Hight, Kenneth; Lai, Shan Tao; Buechele, Andrew; Rielley, Elizabeth; Gan, Hao; Muller, Isabelle S.; Cecil, Richard

    2013-06-13

    The major objective of the baseline glass formulation work was to develop and select glass formulations that are compliant with contractual and processing requirements for each of the LAW waste streams. Other objectives of the work included preparation and characterization of glasses with respect to the properties of interest, optimization of sulfate loading in the glasses, evaluation of ability to achieve waste loading limits, testing to demonstrate compatibility of glass melts with melter materials of construction, development of glass formulations to support ILAW qualification activities, and identification of glass formulation issues with respect to contract specifications and processing requirements.

  6. A new casting defect healing technology

    SciTech Connect (OSTI)

    Hodge, E.S.; Reddoch, T.W.; Viswanathan, S.

    1997-01-01

    A new technology is presented for healing of defects in 356 aluminium alloys that provides economic upgrading of these cast alloys. It uses pneumatic isostatic forging (PIF) to produce high quality Al alloys products with enhanced mechanical properties uniform throughout the part, allowing higher design allowables and increased usage of Al alloy castings. The fundamental mechanism underlying PIF is a single mode plastic deformation process that uses isostatic application of pressures for 10-30 seconds at temperature. The process can be integrated in-line with other production operations, i.e., using the latent heat from the previous casting step. Results of applying the PIF process indicate lower cost and significant improvement in mechanical properties that rival and often exceed corresponding properties of other technologies like hot isostatic pressing and related processes. This process offers many advantages that are described in this paper in addition to presenting case histories of property enhancement by PIF and the mechanism responsible for property enhancement.

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

    SciTech Connect (OSTI)

    Harry Littleton; John Griffin

    2011-07-31

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

  8. Compound cast product and method for producing a compound cast product

    DOE Patents [OSTI]

    Meyer, Thomas N.; Viswanathan, Srinath

    2002-09-17

    A compound cast product is formed in a casting mold (14) having a mold cavity (16) sized and shaped to form the cast product. A plurality of injectors (24) is supported from a bottom side (26) of the casting mold (14). The injectors (24) are in fluid communication with the mold cavity (16) through the bottom side (26) of the casting mold (14). A molten material holder furnace (12) is located beneath the casting mold (14). The holder furnace (12) defines molten material receiving chambers (36) configured to separately contain supplies of two different molten materials (37, 38). The holder furnace (12) is positioned such that the injectors (24) extend downward into the receiving chamber (36). The receiving chamber (36) is separated into at least two different flow circuits (51, 52). A first molten material (37) is received in a first flow circuit (51), and a second molten material (38) is received into a second flow circuit (52). The first and second molten materials (37, 38) are injected into the mold cavity (16) by the injectors (24) acting against the force of gravity. The injectors (24) are positioned such that the first and second molten materials (37, 38) are injected into different areas of the mold cavity (16). The molten materials (37, 38) are allowed to solidify and the resulting compound cast product is removed from the mold cavity (16).

  9. The recycling of the coal fly ash in glass production

    SciTech Connect (OSTI)

    Erol, M.M.; Kucukbayrak, S.; Ersoy-Mericboyu, A.

    2006-09-15

    The recycling of fly ash obtained from the combustion of coal in thermal power plant has been studied. Coal fly ash was vitrified by melting at 1773 K for 5 hours without any additives. The properties of glasses produced from coal fly ash were investigated by means of Differential Thermal Analysis (DTA), X-ray Diffraction (XRD) and Scanning Electron Microscopy (SEM) techniques. DTA study indicated that there was only one endothermic peak at 1003 K corresponding to the glass transition temperature. XRD analysis showed the amorphous state of the glass sample produced from coal fly ash. SEM investigations revealed that the coal fly ash based glass sample had smooth surface. The mechanical, physical and chemical properties of the glass sample were also determined. Recycling of coal fly ash by using vitrification technique resulted to a glass material that had good mechanical, physical and chemical properties. Toxicity characteristic leaching procedure (TCLP) results showed that the heavy metals of Pb, Cr, Zn and Mn were successfully immobilized into the glass. It can be said that glass sample obtained by the recycling of coal fly ash can be taken as a non-hazardous material. Overall, results indicated that the vitrification technique is an effective way for the stabilization and recycling of coal fly ash.

  10. Modeling of casting microstructures and defects

    SciTech Connect (OSTI)

    Shapiro, A.B.; Summers, L.T.; Eckels, D.J.; Sahai, V.

    1997-09-26

    Casting is an ancient art that has been a trial-and-error process for more than 4000 years. To predict the size, shape, and quality of a cast product, casting manufacturers typically cast full-size prototypes. If one part of the process is done incorrectly, the entire process is repeated until an acceptable product is achieved. One way to reduce the time, cost, and waste associated with casting is to use computer modeling to predict not only the quality of a product on the macro- scale, such as distortion and part shape, but also on the micro-scale such as grain defects. Modeling of solidification is becoming increasingly feasible with the advent of parallel computers. There are essentially two approaches to solidification modeling.The first is that of macro-modeling where heat transfer codes model latent heat release during solidification as a constant and based solely on the local temperature. This approach is useful in predicting large scale distortion and final part shape. The second approach, micro-modeling, is more fundamental. The micro-models estimate the latent heat release during solidification using nucleation and grain growth kinetics. Micro-models give insight into cast grain morphology and show promise in the future to predict engineering properties such as tensile strength. The micro-model solidification kinetics can be evaluated using first principles or they can be evaluated using experiments. This work describes an implementation of a micro-model for uranium which uses experimental results to estimate nucleation and growth kinetics.

  11. Technetium Getters to Improve Cast Stone Performance

    SciTech Connect (OSTI)

    Neeway, James J.; Lawter, Amanda R.; Serne, R. Jeffrey; Asmussen, Robert M.; Qafoku, Nikolla

    2015-10-15

    The cementitious material known as Cast Stone has been selected as the preferred waste form for solidification of aqueous secondary liquid effluents from the Hanford Tank Waste Treatment and Immobilization Plant (WTP) process condensates and low-activity waste (LAW) melter off-gas caustic scrubber effluents. Cast Stone is also being evaluated as a supplemental immobilization technology to provide the necessary LAW treatment capacity to complete the Hanford tank waste cleanup mission in a timely and cost effective manner. Two radionuclides of particular concern in these waste streams are technetium-99 (99Tc) and iodine-129 (129I). These radioactive tank waste components contribute the most to the environmental impacts associated with the cleanup of the Hanford site. A recent environmental assessment of Cast Stone performance, which assumes a diffusion controlled release of contaminants from the waste form, calculates groundwater in excess of the allowable maximum permissible concentrations for both contaminants. There is, therefore, a need and an opportunity to improve the retention of both 99Tc and 129I in Cast Stone. One method to improve the performance of Cast Stone is through the addition of “getters” that selectively sequester Tc and I, therefore reducing their diffusion out of Cast Stone. In this paper, we present results of Tc and I removal from solution with various getters with batch sorption experiments conducted in deionized water (DIW) and a highly caustic 7.8 M Na Ave LAW simulant. In general, the data show that the selected getters are effective in DIW but their performance is comprised when experiments are performed with the 7.8 M Na Ave LAW simulant. Reasons for the mitigated performance in the LAW simulant may be due to competition with Cr present in the 7.8 M Na Ave LAW simulant and to a pH effect.

  12. Hermetic fiber optic-to-metal connection technique

    DOE Patents [OSTI]

    Kramer, Daniel P.

    1992-09-01

    A glass-to-glass hermetic sealing technique is disclosed which can be used to splice lengths of glass fibers together. A solid glass preform is inserted into the cavity of a metal component which is then heated to melt the glass. An end of an optical fiber is then advanced into the molten glass and the entire structure cooled to solidify the glass in sealing engagement with the optical fiber end and the metal cavity. The surface of the re-solidified glass may be machined for mating engagement with another component to make a spliced fiber optic connection. The resultant structure has a helium leak rate of less than 1.times.10.sup.-8 cm.sup.3 /sec.

  13. Method for fabricating transistors using crystalline silicon devices on glass

    DOE Patents [OSTI]

    McCarthy, Anthony M.

    1997-01-01

    A method for fabricating transistors using single-crystal silicon devices on glass. This method overcomes the potential damage that may be caused to the device during high voltage bonding and employs a metal layer which may be incorporated as part of the transistor. This is accomplished such that when the bonding of the silicon wafer or substrate to the glass substrate is performed, the voltage and current pass through areas where transistors will not be fabricated. After removal of the silicon substrate, further metal may be deposited to form electrical contact or add functionality to the devices. By this method both single and gate-all-around devices may be formed.

  14. DWPF GLASS BEADS AND GLASS FRIT TRANSPORT DEMONSTRATION

    SciTech Connect (OSTI)

    Adamson, D; Bradley Pickenheim, B

    2008-11-24

    DWPF is considering replacing irregularly shaped glass frit with spherical glass beads in the Slurry Mix Evaporator (SME) process to decrease the yield stress of the melter feed (a non-Newtonian Bingham Plastic). Pilot-scale testing was conducted on spherical glass beads and glass frit to determine how well the glass beads would transfer when compared to the glass frit. Process Engineering Development designed and constructed the test apparatus to aid in the understanding and impacts that spherical glass beads may have on the existing DWPF Frit Transfer System. Testing was conducted to determine if the lines would plug with the glass beads and the glass frit slurry and what is required to unplug the lines. The flow loop consisted of vertical and horizontal runs of clear PVC piping, similar in geometry to the existing system. Two different batches of glass slurry were tested: a batch of 50 wt% spherical glass beads and a batch of 50 wt% glass frit in process water. No chemicals such as formic acid was used in slurry, only water and glass formers. The glass beads used for this testing were commercially available borosilicate glass of mesh size -100+200. The glass frit was Frit 418 obtained from DWPF and is nominally -45+200 mesh. The spherical glass beads did not have a negative impact on the frit transfer system. The transferring of the spherical glass beads was much easier than the glass frit. It was difficult to create a plug with glass bead slurry in the pilot transfer system. When a small plug occurred from setting overnight with the spherical glass beads, the plug was easy to displace using only the pump. In the case of creating a man made plug in a vertical line, by filling the line with spherical glass beads and allowing the slurry to settle for days, the plug was easy to remove by using flush water. The glass frit proved to be much more difficult to transfer when compared to the spherical glass beads. The glass frit impacted the transfer system to the point

  15. Comparative study of local atomic structures in Zr{sub 2}Cu{sub x}Ni{sub 1−x} (x = 0, 0.5, 1) metallic glasses

    SciTech Connect (OSTI)

    Huang, Yuxiang; Huang, Li; Wang, C. Z.; Ho, K. M.; Kramer, M. J.

    2015-11-21

    Extensive analysis has been performed to understand the key structural motifs accounting for the difference in glass forming ability in the Zr-Cu and Zr-Ni binary alloy systems. Here, the reliable atomic structure models of Zr{sub 2}Cu{sub x}Ni{sub 1−x} (x = 0, 0.5, 1) are constructed using the combination of X-ray diffraction experiments, ab initio molecular dynamics simulations and a constrained reverse Monte Carlo method. We observe a systematic variation of the interatomic distance of different atomic pairs with respect to the alloy composition. The ideal icosahedral content in all samples is limited, despite the high content of five-fold symmetry motifs. We also demonstrate that the population of Z-clusters in Zr{sub 2}Cu glass is much higher than that in the Zr{sub 2}Ni and Zr{sub 2}Cu{sub 0.5}Ni{sub 0.5} samples. And Z12 〈0, 0, 12, 0〉 Voronoi polyhedra clusters prefer to form around Cu atoms, while Ni-centered clusters are more like Z11 〈0, 2, 8, 1〉 clusters, which is less energetically stable compared to Z12 clusters. These two different structural properties may account for the higher glass forming ability of Zr{sub 2}Cu alloy than that of Zr{sub 2}Ni alloy.

  16. 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 ...

  17. Clean Cast Steel Technology - Machinability and Technology Transfer

    SciTech Connect (OSTI)

    C. E. Bates; J. A. Griffin

    2000-05-01

    There were two main tasks in the Clean Cast Steel Technology - Machinability and Technology Transfer Project. These were (1) determine the processing facts that control the machinability of cast steel and (2) determine the ability of ladle stirring to homogenize ladle temperature, reduce the tap and pouring temperatures, and reduce casting scrap.

  18. Gelcasting Alumina Cores for Investment Casting

    SciTech Connect (OSTI)

    Janney, M A; Klug, F J

    2001-01-01

    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.

  19. Roll Casting of Al-25%Si

    SciTech Connect (OSTI)

    Haga, Toshio [Osaka Institute of Technology, Omiya Asahiku Osaka city 535-8585 (Japan); Harada, Hideto [Graduate School of Osaka Institute of Technology, Omiya Asahiku Osaka city 535-8585 (Japan); Watari, Hisaki [Gunma University, Kiryu city, 376-8515 (Japan)

    2011-05-04

    Strip casting of Al-25%Si strip was tried using an unequal diameter twin roll caster. The diameter of the lower roll (large roll) was 1000 mm and the diameter of the upper roll (small roll) was 250 mm. Roll material was mild steel. The sound strip could be cast at the speeds ranging from 8 m/min to 12 m/min. The strip did not stick to the roll without the parting material. The primary Si, which existed at centre area of the thickness direction, was larger than that which existed at other area. The size of the primary Si was smaller than 0.2 mm. Eutectic Si was smaller 5 {mu}m. The as-cast strip was ranging from 2 mm to 3 mm thick and its width was 100 mm. The as-cast strip could be hot rolled down to 1 mm. The hot rolled strip was cold rolled. The primary Si became smaller and the pore occurred around the primary Si after the rolling.

  20. 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.

    2012-09-01

    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.

  1. Metallic coatings on silicon substrates, and methods of forming metallic coatings on silicon substrates

    DOE Patents [OSTI]

    Branagan, Daniel J.; Hyde, Timothy A.; Fincke, James R.

    2008-03-11

    The invention includes methods of forming a metallic coating on a substrate which contains silicon. A metallic glass layer is formed over a silicon surface of the substrate. The invention includes methods of protecting a silicon substrate. The substrate is provided within a deposition chamber along with a deposition target. Material from the deposition target is deposited over at least a portion of the silicon substrate to form a protective layer or structure which contains metallic glass. The metallic glass comprises iron and one or more of B, Si, P and C. The invention includes structures which have a substrate containing silicon and a metallic layer over the substrate. The metallic layer contains less than or equal to about 2 weight % carbon and has a hardness of at least 9.2 GPa. The metallic layer can have an amorphous microstructure or can be devitrified to have a nanocrystalline microstructure.

  2. Taiwan Glass Industry Corp | Open Energy Information

    Open Energy Info (EERE)

    Taiwan Glass Industry Corp Place: Taipei, Taiwan Zip: 10566 Product: Engaged in the manufacturing, processing and selling of various types of glass. References: Taiwan Glass...

  3. Xinyi Glass Holdings Limited | Open Energy Information

    Open Energy Info (EERE)

    in the produciton of float glass, automobile glass, construction glass and curtain wall. Coordinates: 23.046499, 113.735817 Show Map Loading map... "minzoom":false,"mappi...

  4. Application of the metal compression forming process for the production of an aluminum alloy component

    SciTech Connect (OSTI)

    Viswanathan, S.; Porter, W.D.; Ren, W.; Purgert, R.M.

    1997-01-01

    Metal Compression Forming (MCF) is a variant of the squeeze casting process, in which molten metal is allowed to solidify under pressure in order to close porosity and form a sound part. MCF applies pressure on the entire mold face, thereby directing pressure on all regions of the casting. It also enhances the solidification rate of the metal, promoting a very fine grain structure which results in improved properties. Consequently, the process is capable of producing parts with properties close to that of forgings, while retaining the near net shape, complex geometry, and relatively low cost of the casting process.

  5. Glass strengthening and patterning methods

    SciTech Connect (OSTI)

    Harper, David C; Wereszczak, Andrew A; Duty, Chad E

    2015-01-27

    High intensity plasma-arc heat sources, such as a plasma-arc lamp, are used to irradiate glass, glass ceramics and/or ceramic materials to strengthen the glass. The same high intensity plasma-arc heat source may also be used to form a permanent pattern on the glass surface--the pattern being raised above the glass surface and integral with the glass (formed of the same material) by use of, for example, a screen-printed ink composition having been irradiated by the heat source.

  6. Shedding Synchrotron Light on a Puzzle of Glasses

    ScienceCinema (OSTI)

    Chumakov, Aleksandr [European Synchrotron Radiation Facility, Grenoble, France

    2010-01-08

    Vibrational dynamics of glasses remains a point of controversial discussions. In particular, the density of vibrational states (DOS) reveals an excess of states above the Debye model called "boson peak." Despite the fact that this universal feature for all glasses has been known for more than 35 years, the nature of the boson peak is still not understood. The application of nuclear inelastic scattering via synchrotron radiation perhaps provides a clearer, more consistent picture of the subject. The distinguishing features of nuclear inelastic scattering relative to, e.g., neutron inelastic scattering, are ideal momentum integration and exact scaling of the DOS in absolute units. This allows for reliable comparison to data from other techniques such as Brillouin light scattering. Another strong point is ideal isotope selectivity: the DOS is measured for a single isotope with a specific low-energy nuclear transition. This allows for special "design" of an experiment to study, for instance, the dynamics of only center-of-mass motions. Recently, we have investigated the transformation of the DOS as a function of several key parameters such as temperature, cooling rate, and density. In all cases the transformation of the DOS is sufficiently well described by a transformation of the continuous medium, in particular, by changes of the macroscopic density and the sound velocity. These results suggest a collective sound-like nature of vibrational dynamics in glasses and cast doubts on microscopic models of glass dynamics. Further insight can be obtained in combined studies of glass with nuclear inelastic and inelastic neutron scattering. Applying two techniques, we have measured the energy dependence of the characteristic correlation length of atomic motions. The data do not reveal localization of atomic vibrations at the energy of the boson peak. Once again, the results suggest that special features of glass dynamics are related to extended motions and not to local models.

  7. Magnesium phosphate glass cements with ceramic-type properties

    DOE Patents [OSTI]

    Sugama, Toshifumi; Kukacka, Lawrence E.

    1984-03-13

    Rapid setting magnesium phosphate (Mg glass) cementitious materials consisting of magnesium phosphate cement paste, polyborax and water-saturated aggregate exhibiting rapid setting and high early strength characteristics. The magnesium glass cement is prepared from a cation-leachable powder and a bivalent metallic ion-accepting liquid such as an aqueous solution of diammonium phosphate and ammonium polyphosphate. The cation-leachable powder includes a mixture of two different magnesium oxide powders processed and sized differently which when mixed with the bivalent metallic ion-accepting liquid provides the magnesium glass cement consisting primarily of magnesium ortho phosphate tetrahydrate, with magnesium hydroxide and magnesium ammonium phosphate hexahydrate also present. The polyborax serves as a set-retarder. The resulting magnesium mono- and polyphosphate cements are particularly suitable for use as a cementing matrix in rapid repair systems for deteriorated concrete structures as well as construction materials and surface coatings for fireproof structures.

  8. Magnesium-phosphate-glass cements with ceramic-type properties

    DOE Patents [OSTI]

    Sugama, T.; Kukacka, L.E.

    1982-09-23

    Rapid setting magnesium phosphate (Mg glass) cementitious materials consisting of magnesium phosphate cement paste, polyborax and water-saturated aggregate, exhibits rapid setting and high early strength characteristics. The magnesium glass cement is prepared from a cation-leachable powder and a bivalent metallic ion-accepting liquid such as an aqueous solution of diammonium phosphate and ammonium polyphosphate. The cation-leachable powder includes a mixture of two different magnesium oxide powders processed and sized differently which when mixed with the bivalent metallic ion-accepting liquid provides the magnesium glass cement consisting primarily of magnesium ortho phosphate tetrahydrate, with magnesium hydroxide and magnesium ammonium phosphate hexahydrate also present. The polyborax serves as a set-retarder. The resulting magnesium mono- and polyphosphate cements are particularly suitable for use as a cementing matrix in rapid repair systems for deteriorated concrete structures as well as construction materials and surface coatings for fireproof structures.

  9. CADMIUM PHOSPHATE GLASS

    DOE Patents [OSTI]

    Carpenter, H.W.; Johnson, P.D.

    1963-04-01

    A method of preparing a cadmium phosphate glass that comprises providing a mixture of solid inorganic compounds of cadmuim and phosphate having vaporizable components and heating the resulting composition to a temperature of at least 850 un. Concent 85% C is presented. (AEC)

  10. Barstow heliostat mirror glass characterization

    SciTech Connect (OSTI)

    Lind, M.A.; Buckwalter, C.Q.

    1980-09-01

    The technical analysis performed on the special run of low iron float glass procured from the Ford Glass Division for the ten megawatt solar thermal/electric pilot power plant to be constructed at Barstow, California is discussed. The topics that are addressed include the optical properties and the relative durability of the glass. Two optical parameters, solar transmittance and optical flatness, were measured as referenced in the specification and found to be better than the stated tolerances. The average solar transmittance exceeded 0.890 transmittance units. The glass also exhibited optical angular flatness deviations less than +-1.0 mrad as required. Both qualitative and quantitative accelerated weathering tests were performed on the glass in order to compare its durability to other soda lime float glass and alternate composition glasses of interest to the solar community. In both the quantitative leaching experiments and the more qualitative room temperature and elevated temperature water vapor exposure experiments the heliostat glass exhibited the same characteristics as the other soda-lime silicate float glasses. As a final test for mirroring compatability, selected samples of the production run of the glass were sent to four different commercial manufacturers for mirror coating. None of the manufacturers reported any difficulty silvering the glass. Based on the tests performed, the glass meets or exceeds all optical specifications for the Barstow heliostat field.

  11. Computer modeling of electromagnetic fields and fluid flows for edge containment in continuous casting

    SciTech Connect (OSTI)

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

    1996-02-01

    A computer model was developed to predict eddy currents and fluid flows in molten steel. The model was verified by comparing predictions with experimental results of liquid-metal containment and fluid flow in electromagnetic (EM) edge dams (EMDs) designed at Inland Steel for twin-roll casting. The model can optimize the EMD design so it is suitable for application, and minimize expensive, time-consuming full-scale testing. Numerical simulation was performed by coupling a three-dimensional (3-D) finite-element EM code (ELEKTRA) and a 3-D finite-difference fluids code (CaPS-EM) to solve heat transfer, fluid flow, and turbulence transport in a casting process that involves EM fields. ELEKTRA is able to predict the eddy- current distribution and the electromagnetic forces in complex geometries. CaPS-EM is capable of modeling fluid flows with free surfaces. Results of the numerical simulation compared well with measurements obtained from a static test.

  12. Sodium compatibility of refractory metal alloy/304L braze joints

    SciTech Connect (OSTI)

    Hosking, F.M.

    1984-05-01

    Vacuum induction brazing of Mo, Re, Ta, and W aloys to 304L stainless steel with AWS BNi filler metals was investigated. Metal powder (BNi-5 and BNi-7) and metallic glass (BNi-3 and modified BNi-5) brazing alloys were evaluated. Excellent braze joints were obtained with the BNi-3 and modified BNi-5 metallic glass foils. Cracks and porosity were observed in the metal powder BNi-5 and BNi-7 brazes. The as-brazed, refractory metal/304L samples were also qualified in a sodium environment of 1073/sup 0/K (1472/sup 0/F)/130 hours/2 and 100 ppM oxygen concentration. There was no significant chemical corrosive attack observed on any of the sodium samples and weight changes were generally negligible. Braze separation along the refractory metal interface and crack growth in the filler metal, however, were observed in the metal powder brazes after the sodium exposures. As a result, the metal powder fillers were not recommended. A band of discontinuous voids in the metallic glass brazes near the refractory metal interface was also detected. Metallographic, thermal and microprobe analyses revealed that these voids were caused by a diffusion mechanism called Kirkendall porosity. Since the voids were not connected and would not provide a leak path, the metallic glass filler metals were recommended for brazing refractory metal alloys to 304L and for subsequent sodium exposures.

  13. Process for slip casting textured tubular structures

    DOE Patents [OSTI]

    Steinlage, Greg A.; Trumble, Kevin P.; Bowman, Keith J.

    2002-01-01

    A process for centrifugal slip casting a textured hollow tube. A slip made up of a carrier fluid and a suspended powder is introduced into a porous mold which is rotated at a speed sufficient to create a centrifugal force that forces the slip radially outward toward the inner surface of the mold. The suspended powder, which is formed of particles having large dimensional aspect ratios such as particles of superconductive BSCCO, settles in a textured fashion radially outward toward the mold surface. The carrier fluid of the slip passes by capillary action radially outward around the settled particles and into the absorbent mold. A layer of mold release material is preferably centrifugally slip cast to cover the mold inner surface prior to the introduction of the BSCCO slip, and the mold release layer facilitates removal of the BSCCO greenbody from the mold without fracturing.

  14. Phase Transformation in Cast Superaustenitic Stainless Steels

    SciTech Connect (OSTI)

    Nathaniel Steven Lee Phillips

    2006-12-12

    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.

  15. Thin Wall Cast Iron: Phase II

    SciTech Connect (OSTI)

    Doru M. Stefanescu

    2005-07-21

    The development of thin-wall technology allows the designers of energy consuming equipment to select the most appropriate material based on cost/material properties considerations, and not solely on density. The technology developed in this research project will permit the designers working for the automotive industry to make a better informed choice between competing materials and thin wall cast iron, thus decreasing the overall cost of the automobile.

  16. IMPROVED MAGNESIUM OXIDE SLIP CASTING METHOD

    DOE Patents [OSTI]

    Stoddard, S.D.; Nuckolls, D.E.

    1963-12-31

    A process for making an aqueous magnesium oxide slip casting slurry comprising the steps of mixing finely ground fused magnesium oxide with water, milling the slurry for at least 30 hours at a temperature of 2-10 deg C (the low temperature during milling inhibiting the formation of hydrated magnesium oxide), discharging the slurry from the mill, adding hydrochloric acid as a deflocculent, and adding a scum inhibitor is presented. (AEC)

  17. Symposium on electroslag component casting: proceedings

    SciTech Connect (OSTI)

    Judkins, R.R.; Hobday, J.M.

    1984-03-01

    The US Department of Energy (DOE), Office of Fossil Energy, Office of Surface Coal Gasification, has established a Materials Program to develop and apply appropriate materials to coal gasification plant components. The overall goals of the Surface Gasification Materials Program (SGMP) are to improve operational reliability and system durability and to reduce fabrication and operating costs of coal gasification plant components. The SGMP Electroslag Component Casting Project is directed to the development of electroslag casting (ESC) technology for use in coal conversion components such as valve bodies, pump housings, and pipe fittings. The aim is to develop a sufficient data base to permit ESC to become an ASME Code-accepted process. It is also intended to transfer the ESC process technology to private industry. This symposium was planned to discuss not only the SGMP Electroslag Component Casting Project but the activities and experiences of other organizations as well. The symposium addressed descriptions of electroslag processes; a worldwide perspective on the status of ESC technology; and details of production, mechanical properties, economics, and use of ESC for coal gasification components. Ten papers were presented, and a panel discussion was held to provide participants an opportunity to express their opinions and to offer recommendations on the content of the DOE program. This document constitutes the proceedings of that symposium. The papers included here are minimally edited transcripts of the presentations made at the symposium. All papers have been processed for inclusion in the Energy Data Base.

  18. Method of forming a relatively stable slip of silicon metal particles and yttrium containing particles

    DOE Patents [OSTI]

    Dickie, Ray A.; Mangels, John A.

    1984-01-01

    The method concerns forming a relatively stable slip of silicon metal particles and yttrium containing particles. In one embodiment, a casting slip of silicon metal particles is formed in water. Particles of a yttrium containing sintering aid are added to the casting slip. The yttrium containing sintering aid is a compound which has at least some solubility in water to form Y.sup.+3 ions which have a high potential for totally flocculating the silicon metal particles into a semiporous solid. A small amount of a fluoride salt is added to the casting slip which contains the yttrium containing sintering aid. The fluoride salt is one which will produce fluoride anions when dissolved in water. The small amount of the fluoride anions produced are effective to suppress the flocculation of the silicon metal particles by the Y.sup.+3 ions so that all particles remain in suspension in the casting slip and the casting slip has both an increased shelf life and can be used to cast articles having a relatively thick cross-section. The pH of the casting slip is maintained in a range from 7.5 to 9. Preferably, the fluoride salt used is one which is based on a monovalent cation such as sodium or ammonia. The steps of adding the yttrium containing sintering aid and the fluoride salt may be interchanged if desired, and the salt may be added to a solution containing the sintering aid prior to addition of the silicon metal particles.

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

    SciTech Connect (OSTI)

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

    2007-01-01

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

  20. Erratum: “Effect of hydrothermal condition on the formation of multi-component oxides of Ni-based metallic glass under high temperature water near the critical point” [AIP Advances 5, 077132 (2015)

    SciTech Connect (OSTI)

    Kim, J. S.; Kim, S. Y.; Kim, D. H.; Ott, R. T.; Kim, H. G.; Lee, M. H.

    2015-12-30

    In the original manuscript, M. H. Lee’s affiliation number was incorrectly listed as 1. M. H. Lee’s correct affiliation number is 2 (Rare Metals R&D Group, Korea Institute of Industrial Technology, Incheon 406-840, South Korea). Furthermore, this change affects no other part of the paper.

  1. Erratum: Effect of hydrothermal condition on the formation of multi-component oxides of Ni-based metallic glass under high temperature water near the critical point [AIP Advances 5, 077132 (2015)

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

    Kim, J. S.; Kim, S. Y.; Kim, D. H.; Ott, R. T.; Kim, H. G.; Lee, M. H.

    2015-12-30

    In the original manuscript, M. H. Lees affiliation number was incorrectly listed as 1. M. H. Lees correct affiliation number is 2 (Rare Metals R&D Group, Korea Institute of Industrial Technology, Incheon 406-840, South Korea). Furthermore, this change affects no other part of the paper.

  2. Centrifugal Casting Features/Metallurgical Characterization of Aluminum Alloys

    SciTech Connect (OSTI)

    Chirita, G.; Soares, D.; Cruz, D.; Silva, F. S. [Mechanical Engineering Department, School of Engineering, Minho University (Portugal); Stefanescu, I. [Faculty of Mechanical Engineering, Dunarea de Jos University Galati (Romania)

    2008-02-15

    This paper deals with the study of centrifugal effects on aluminium castings under high G values. Most of the studies in this domain (FGMs obtained by centrifugal casting) deal with functionally graded composites reinforced with a solid phase such as silicon particles or others. However, in this study it will be shown that unreinforced aluminium alloys may be significantly influenced by the centrifugal effect and that functionally graded castings are also obtained. It has been observed that the centrifugal effect may increase in some alloys, depending on the relative position in the castings, the rupture strength by approx. 50%, and rupture strain by about 300%, as compared to the gravity casting technique. The Young's modulus may also increase by about 20%. It has also been reported that in vertical centrifugal castings there are mainly three aspects that affect the components thus obtained, namely: fluid dynamics; vibration (inherent to the system); and centrifugal force. These features have a different effect on the castings depending on the aluminium alloy. In this paper, an analysis of the most important effects of the centrifugal casting process on metallurgical features is conducted. A solidification characterization at several points along the mould will be made in order to have an accurate idea of both the fluid dynamics inside the mould during the casting and the solidification behavior in different parts of the component. These two analyses will be related to the metallurgical properties (phase distribution; SDAS; eutectic silicon content and shape, pores density and shape) along the component and mainly along the direction of the centrifugal pressure. A comparison between castings obtained by both centrifugal casting technique and gravity casting technique is made for reference (gravity casting)

  3. Profiles in garbage glass containers

    SciTech Connect (OSTI)

    Miller, C.

    1997-09-01

    Glass containers are made from sand, limestone, soda ash, cullet (crushed bottles), and various additives, including those used to color brown, green, or blue bottles. Sixty percent of the glass used in the US is clear (flint) and one-fourth is brown (amber). Almost half of the green bottles are imported wind and beer bottles. Other glass products include flat glass such as windows; fiberglass insulation; and glassware. These products use different manufacturing processes and different additives than container glass. This profile covers only container glass. Glass bottles are commonly collected in curb-side programs. Losses due to breakage and the abrasiveness of glass during collection and processing offset their low collection and processing costs. Breakage solutions include installation of interior baffles or nets in the collection trucks, special glass-only truck compartments, and limiting the number of times glass is transferred after collection before final processing. Ten states require deposits on glass bottles for beer and soft drinks and related items.

  4. Method of producing metallic materials

    DOE Patents [OSTI]

    Branagan, Daniel J.

    2004-02-10

    The invention includes a method of producing a hard metallic material by forming a mixture containing at least 55% iron and at least one of B, C, Si and P. The mixture is formed into an alloy and cooled to form a metallic material having a hardness greater than about 9.2 GPa. The invention includes a method of forming a wire by combining a metal strip and a powder. The strip and the powder are rolled to form a wire containing at least 55% iron and from 2-7 additional elements including at least one of C, Si and B. The invention also includes a method of forming a hardened surface on a substrate by processing a solid mass to form a powder, applying the powder to a surface to form a layer containing metallic glass, and converting the glass to a crystalline material having a nanocrystalline grain size.

  5. High thermal expansion, sealing glass

    DOE Patents [OSTI]

    Brow, Richard K.; Kovacic, Larry

    1993-01-01

    A glass composition for hermetically sealing to high thermal expansion materials such as aluminum alloys, stainless steels, copper, and copper/beryllium alloys, which includes between about 10 and about 25 mole percent Na.sub.2 O, between about 10 and about 25 mole percent K.sub.2 O, between about 5 and about 15 mole percent Al.sub.2 O.sub.3, between about 35 and about 50 mole percent P.sub.2 O.sub.5 and between about 5 and about 15 mole percent of one of PbO, BaO, and mixtures thereof. The composition, which may also include between 0 and about 5 mole percent Fe.sub.2 O.sub.3 and between 0 and about 10 mole percent B.sub.2 O.sub.3, has a thermal expansion coefficient in a range of between about 160 and 210.times.10-7/.degree.C. and a dissolution rate in a range of between about 2.times.10.sup.- 7 and 2.times.10.sup.-9 g/cm.sup.2 -min. This composition is suitable to hermetically seal to metallic electrical components which will be subjected to humid environments over an extended period of time.

  6. High thermal expansion, sealing glass

    DOE Patents [OSTI]

    Brow, R.K.; Kovacic, L.

    1993-11-16

    A glass composition is described for hermetically sealing to high thermal expansion materials such as aluminum alloys, stainless steels, copper, and copper/beryllium alloys, which includes between about 10 and about 25 mole percent Na[sub 2]O, between about 10 and about 25 mole percent K[sub 2]O, between about 5 and about 15 mole percent Al[sub 2]O[sub 3], between about 35 and about 50 mole percent P[sub 2]O[sub 5] and between about 5 and about 15 mole percent of one of PbO, BaO, and mixtures thereof. The composition, which may also include between 0 and about 5 mole percent Fe[sub 2]O[sub 3] and between 0 and about 10 mole percent B[sub 2]O[sub 3], has a thermal expansion coefficient in a range of between about 160 and 210[times]10[sup [minus]7]/C and a dissolution rate in a range of between about 2[times]10[sup [minus]7] and 2[times]10[sup [minus]9]g/cm[sup 2]-min. This composition is suitable to hermetically seal to metallic electrical components which will be subjected to humid environments over an extended period of time.

  7. Phosphate glass useful in high power lasers

    DOE Patents [OSTI]

    Hayden, Joseph S.; Sapak, David L.; Ward, Julia M.

    1990-01-01

    A low- or no-silica phosphate glass useful as a laser medium and having a high thermal conductivity, K.sub.90.degree. C. >0.8 W/mK, and a low coefficient of thermal expansion, .alpha..sub.20.degree.-40.degree. C. <80.times.10.sup.-7 /.degree.C., consists essentially of (on a batch composition basis): the amounts of Li.sub.2 O and Na.sub.2 O providing an average alkali metal ionic radius sufficiently low whereby said glass has K.sub.90.degree. C. >0.8 W/mK and .alpha..sub.20.degree.-40.degree. C. <80.times.10.sup.-7 /.degree.C., and wherein, when the batch composition is melted in contact with a silica-containing surface, the final glass composition contains at most about 3.5 mole % of additional silica derived from such contact during melting. The Nd.sub.2 O.sub.3 can be replaced by other lasing species.

  8. ITP Glass: Glass Industry of the Future: Energy and Environmental Profile

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

    of the U.S. Glass Industry; April, 2002 | Department of Energy Glass Industry of the Future: Energy and Environmental Profile of the U.S. Glass Industry; April, 2002 ITP Glass: Glass Industry of the Future: Energy and Environmental Profile of the U.S. Glass Industry; April, 2002 glass2002profile.pdf (4.73 MB) More Documents & Publications ITP Glass: Industrial Glass Bandwidth Analysis Final Report, August 2007 ITP Glass: A Clear Vision for a Bright Future ITP Glass: Glass Industry

  9. Mixed polyanion glass cathodes: Glass-state conversion reactions

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

    Kercher, Andrew K.; Kolopus, James A.; Carroll, Kyler; Unocic, Raymond R.; Kirklin, S.; Wolverton, C.; Stooksbury, Shelby L.; Boatner, Lynn A.; Dudney, Nancy J.

    2015-01-01

    Mixed polyanion (MP) glasses can undergo glass-state conversion (GSC) reactions to provide an alternate class of high-capacity cathode materials. GSC reactions have been demonstrated in phosphate/vanadate glasses with Ag, Co, Cu, Fe, and Ni cations. These MP glasses provided high capacity and good high power performance, but suffer from moderate voltages, large voltage hysteresis, and significant capacity fade with cycling. Details of the GSC reaction have been revealed by x-ray absorption spectroscopy, electron microscopy, and energy dispersive x-ray spectroscopy of ex situ cathodes at key states of charge. Using the Open Quantum Materials Database (OQMD), a computational thermodynamic model hasmore » been developed to predict the near-equilibrium voltages of glass-state conversion reactions in MP glasses.« less

  10. Mixed polyanion glass cathodes: Glass-state conversion reactions

    SciTech Connect (OSTI)

    Kercher, Andrew K.; Kolopus, James A.; Carroll, Kyler; Unocic, Raymond R.; Kirklin, S.; Wolverton, C.; Stooksbury, Shelby L.; Boatner, Lynn A.; Dudney, Nancy J.

    2015-01-01

    Mixed polyanion (MP) glasses can undergo glass-state conversion (GSC) reactions to provide an alternate class of high-capacity cathode materials. GSC reactions have been demonstrated in phosphate/vanadate glasses with Ag, Co, Cu, Fe, and Ni cations. These MP glasses provided high capacity and good high power performance, but suffer from moderate voltages, large voltage hysteresis, and significant capacity fade with cycling. Details of the GSC reaction have been revealed by x-ray absorption spectroscopy, electron microscopy, and energy dispersive x-ray spectroscopy of ex situ cathodes at key states of charge. Using the Open Quantum Materials Database (OQMD), a computational thermodynamic model has been developed to predict the near-equilibrium voltages of glass-state conversion reactions in MP glasses.

  11. Cast Stainless Steel Aging Research Plan | Department of Energy

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

    Cast Stainless Steel Aging Research Plan Cast Stainless Steel Aging Research Plan This work plan proposes to build a systematic knowledge base for the thermal aging behavior of cast stainless steels (CASSs) within a limited time of five years. The final output of execution of the plan is expected to provide conclusive predictions for the integrity of the CASS components of LWR power plants during the extended service life up to and beyond 60 years. Mechanical and microstructural data obtained

  12. Archeological Applications of XAFS: Prehistorical Paintings And Medieval Glasses

    SciTech Connect (OSTI)

    Farges, F.; Chalmin, E.; Vignaud, C.; Pallot-Frossard, I.; Susini, J.; Bargar, J.; Brown, G.E., Jr.; Menu, M.; /SLAC, SSRL

    2006-10-27

    High-resolution manganese and iron K-edges XANES spectra were collected on several samples of archeological interest: prehistorical paintings and medieval glasses. XANES spectra were collected at the ID21 facility (ESRF, Grenoble, France) using a micro-beam device and at the 11-2 beamline (SSRL, Stanford, USA) using a submillimetric beam. The medieval glasses studied are from gothic glass windows from Normandy (XIVth century). The aim of this study is to help understand the chemical durability of these materials, exposed to weathering since the XIVth century. They are used as analogues of weathered glasses used to dump metallic wastes. These glasses show surficial enrichment in manganese, due to its oxidation from II (glass) to III/IV (surface), which precipitates as amorphous oxy-hydroxides. Similarly, iron is oxidized on the surface and forms ferrihydrite-type aggregates. The prehistorical paintings are from Lascaux and Ekain (Basque country). We choose in that study the black ones, rich in manganese to search for potential evidences of some 'savoir-faire' that the Paleolithic men could have used to realize their paint in rock art, as shown earlier for Fe-bearing pigments. A large number of highly valuable samples, micrometric scaled, were extracted from these frescoes and show large variation in the mineralogical nature of the black pigments used, from an amorphous psilomelane-type to a well-crystallized pyrolusite. Correlation with the crystals morphology helps understanding the know-how of these early artists.

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

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

    ITP Steel: Hydrogen and Nitrogen Control in Ladle and Casting Operations castingops.pdf (875.11 KB) More Documents & Publications Steel Industry Technology Roadmap ITP Steel: ...

  14. Virtual Aluminum Castings An Industrial Application of Integrated...

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

    and cost challenges. Nowhere is this more evident than in the development of designs and manufacturing processes for cast aluminum engine blocks and cylinder heads. Increasing...

  15. Optimization of Squeeze Casting for Aluminum Alloy Parts (Technical...

    Office of Scientific and Technical Information (OSTI)

    project, primarily for squeeze casting different configurations of test bars and plates. ... die of various thickness, a number of test bar inserts with different gating designs ...

  16. AIS/DOE Technology Roadmap Program: Strip Casting: Anticipating...

    Office of Scientific and Technical Information (OSTI)

    Technical Report: AISDOE Technology Roadmap Program: Strip Casting: Anticipating New Routes To Steel Sheet Citation Details In-Document Search Title: AISDOE Technology Roadmap...

  17. AIS/DOE Technology Roadmap Program: Strip Casting: Anticipating...

    Office of Scientific and Technical Information (OSTI)

    AISDOE Technology Roadmap Program: Strip Casting: Anticipating New Routes To Steel Sheet Citation Details In-Document Search Title: AISDOE Technology Roadmap Program: Strip...

  18. Casting Process Simulator 3D Mold Fill an Solidification

    Energy Science and Technology Software Center (OSTI)

    1997-03-06

    The CAPS software is a tool used to setup, simulate, and examine the results from three-dimensional filling and solidification of a sand casting.

  19. Microstructural Modification of a Cast Iron by Magnetic Field Processing

    SciTech Connect (OSTI)

    Kenik, Edward A; Ludtka, Gail Mackiewicz-; Ludtka, Gerard Michael; Wilgen, John B; Kisner, Roger A

    2010-01-01

    The current study deals with the microstructural modification of a nodular cast iron during solidification under the influence of high magnetic fields (up to 18 tesla).

  20. Final Report, Volume 1, Metallurgical Evaluation of Cast Duplex...

    Office of Scientific and Technical Information (OSTI)

    Technical Report: Final Report, Volume 1, Metallurgical Evaluation of Cast Duplex Stainless Steels and their Weldments Citation Details In-Document Search Title: Final Report, ...

  1. Casting Process Simulator 2D Mold Fill and Solidification

    Energy Science and Technology Software Center (OSTI)

    1995-05-06

    The CaPS software is a tool used to setup, simulate, and examine the results from two-dimensional filling and solidification of a sand casting.

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

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

    Enabling Production of Lightweight Magnesium Parts for Near-Term Automotive Applications. ... cost and most productive casting process for producing large and complex automotive parts. ...

  3. ITP Glass: Industrial Glass Bandwidth Analysis Final Report,...

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

    Wolf Gas Technology Institute Energy Utilization Center August 2007 Industrial Glass Bandwidth Analysis FINAL REPORT Prepared by: David M. Rue James Servaites Dr. Warren Wolf ...

  4. Glass Property Models and Constraints for Estimating the Glass...

    Office of Scientific and Technical Information (OSTI)

    Plus the models do not currently address the prediction uncertainties that would be needed ... glass volume projections due to model prediction uncertainties that has to be considered ...

  5. Method of making metal matrix composites reinforced with ceramic particulates

    DOE Patents [OSTI]

    Cornie, J.A.; Kattamis, T.; Chambers, B.V.; Bond, B.E.; Varela, R.H.

    1989-08-01

    Composite materials and methods for making such materials are disclosed in which dispersed ceramic particles are at chemical equilibrium with a base metal matrix, thereby permitting such materials to be remelted and subsequently cast or otherwise processed to form net weight parts and other finished (or semi-finished) articles while maintaining the microstructure and mechanical properties (e.g. wear resistance or hardness) of the original composite. The composite materials of the present invention are composed of ceramic particles in a base metal matrix. The ceramics are preferably carbides of titanium, zirconium, tungsten, molybdenum or other refractory metals. The base metal can be iron, nickel, cobalt, chromium or other high temperature metal and alloys thereof. For ferrous matrices, alloys suitable for use as the base metal include cast iron, carbon steels, stainless steels and iron-based superalloys. 2 figs.

  6. Method of making metal matrix composites reinforced with ceramic particulates

    DOE Patents [OSTI]

    Cornie, James A.; Kattamis, Theodoulos; Chambers, Brent V.; Bond, Bruce E.; Varela, Raul H.

    1989-01-01

    Composite materials and methods for making such materials are disclosed in which dispersed ceramic particles are at chemical equilibrium with a base metal matrix, thereby permitting such materials to be remelted and subsequently cast or otherwise processed to form net weight parts and other finished (or semi-finished) articles while maintaining the microstructure and mechanical properties (e.g. wear resistance or hardness) of the original composite. The composite materials of the present invention are composed of ceramic particles in a base metal matrix. The ceramics are preferably carbides of titanium, zirconium, tungsten, molybdenum or other refractory metals. The base metal can be iron, nickel, cobalt, chromium or other high temperature metal and alloys thereof. For ferrous matrices, alloys suitable for use as the base metal include cast iron, carbon steels, stainless steels and iron-based superalloys.

  7. Method and apparatus for strip casting

    DOE Patents [OSTI]

    Follstaedt, D.W.; Powell, J.C.; Sussman, R.C.; Williams, R.S.

    1991-11-12

    Casting nozzles will provide improved flow conditions with the parameters controlled according to the present invention. The gap relationships between the nozzle slot and exit orifice must be controlled in combination with converging exit passageway to provide a smooth flow without shearing and turbulence in the stream. The nozzle lips are also rounded to improve flow and increase refractory life of the lips of the nozzle. The tundish walls are tapered to provide improve flow for supplying the melt to the nozzle. The nozzle is located about 45[degree] below top dead center for optimum conditions. 2 figures.

  8. Method and apparatus for strip casting

    DOE Patents [OSTI]

    Follstaedt, Donald W.; Powell, John C.; Sussman, Richard C.; Williams, Robert S.

    1991-01-01

    Casting nozzles will provide improved flow conditions with the parameters controlled according to the present invention. The gap relationships between the nozzle slot and exit orifice must be controlled in combination with converging exit passageway to provide a smooth flow without shearing and turbulence in the stream. The nozzle lips are also rounded to improve flow and increase refractory life of the lips of the nozzle. The tundish walls are tapered to provide improve flow for supplying the melt to the nozzle. The nozzle is located about 45.degree. below top dead center for optimum conditions.

  9. Phase Transformations in Cast Duplex Stainless Steels

    SciTech Connect (OSTI)

    Yoon-Jun Kim

    2004-12-19

    Duplex stainless steels (DSS) constitute both ferrite and austenite as a matrix. Such a microstructure confers a high corrosion resistance with favorable mechanical properties. However, intermetallic phases such as {sigma} and {chi} can also form during casting or high-temperature processing and can degrade the properties of the DSS. This research was initiated to develop time-temperature-transformation (TTT) and continuous-cooling-transformation (CCT) diagrams of two types of cast duplex stainless steels, CD3MN (Fe-22Cr-5Ni-Mo-N) and CD3MWCuN (Fe-25Cr-7Ni-Mo-W-Cu-N), in order to understand the time and temperature ranges for intermetallic phase formation. The alloys were heat treated isothermally or under controlled cooling conditions and then characterized using conventional metallographic methods that included tint etching, and also using electron microscopy (SEM, TEM) and wavelength dispersive spectroscopy (WDS). The kinetics of intermetallic-phase ({sigma} + {chi}) formation were analyzed using the Johnson-Mehl-Avrami (MA) equation in the case of isothermal transformations and a modified form of this equation in the case of continuous cooling transformations. The rate of intermetallic-phase formation was found to be much faster in CD3MWCuN than CD3MN due mainly to differences in the major alloying contents such as Cr, Ni and Mo. To examine in more detail the effects of these elements of the phase stabilities; a series of eight steel castings was designed with the Cr, Ni and Mo contents systematically varied with respect to the nominal composition of CD3MN. The effects of varying the contents of alloying additions on the formation of intermetallic phases were also studied computationally using the commercial thermodynamic software package, Thermo-Calc. In general, {sigma} was stabilized with increasing Cr addition and {chi} by increasing Mo addition. However, a delicate balance among Ni and other minor elements such as N and Si also exists. Phase equilibria in

  10. Continuation of Crosscutting Technology Development at Cast

    SciTech Connect (OSTI)

    Yoon, Roe-Hoan

    2012-03-31

    This Final Technical Report describes progress made on the sub-projects awarded in the Cooperative Agreement DE-FC26-05NT42457: Continuation of Crosscutting Technology Development at Center for Advanced Separation Technologies (CAST). The final reports for each sub-project are attached in the appendix. Much of the research to be conducted with Cooperative Agreement funds will be longer-term, high-risk, basic research and will be carried out in five broad areas: a) Solid-solid separation b) Solid-liquid separation c) Chemical/Biological Extraction d) Modeling and Control, and e) Environmental Control.

  11. A Numerical Model of the Temperature Field of the Cast and Solidified Ceramic Material

    SciTech Connect (OSTI)

    Kavicka, Frantisek; Sekanina, Bohumil; Stransky, Karel; Stetina, Josef [Brno University of Technology, Brno, Technicka 2 (Czech Republic); Dobrovska, Jana [Technical University of Ostrava, Ostrava, Tr. 17.listopadu 17 (Czech Republic)

    2010-06-15

    Corundo-baddeleyit material (CBM)--EUCOR--is a heat- and wear-resistant material even at extreme temperatures. This article introduces a numerical model of solidification and cooling of this material in a non-metallic mould. The model is capable of determining the total solidification time of the casting and also the place of the casting which solidifies last. Furthermore, it is possible to calculate the temperature gradient in any point and time, and also determine the local solidification time and the solidification interval of any point. The local solidification time is one of the input parameters for the cooperating model of chemical heterogeneity. This second model and its application on samples of EUCOR prove that the applied method of measurement of chemical heterogeneity provides detailed quantitative information on the material structure and makes it possible to analyse the solidification process. The analysis of this process entails statistical processing of the results of the measurements of the heterogeneity of the components of EUCOR and performs correlation of individual components during solidification. The crystallisation process seems to be very complicated, where the macro- and microscopic segregations differ significantly. The verification of both numerical models was conducted on a real cast 350x200x400 mm block.

  12. Fatigue Life Prediction in Rapid Die Casting - Preliminary Work in View of Current Research

    SciTech Connect (OSTI)

    Chuan Huat Ng [Faculty of Mechanical and Manufacturing Engineering (FKMP), Kolej Universiti Teknologi Tun Hussein Onn (KUiTTHO), P.O.Box 101, 86400 Parit Raja, Batu Pahat, Johor (Malaysia); Grote, Karl-Heinrich [Institut fuer Maschinenkonstruktion, Lehrstuhl Konstruktionstechnik, Otto-von-Guericke University Magdeburg, Universitaetsplatz 2, 39106 Magdeburg (Germany); Baehr, Ruediger [Institut fuer Fertigungstechnik und Qualitaetssicherung, Ur und Umformtechnik, Otto-von-Guericke University Magdeburg, Universitaetsplatz 2, 39106 Magdeburg (Germany)

    2007-05-17

    Numerical simulation technique as a prediction tool is slowly adopted in metal casting industry for predicting design modelling solidification analysis. The reasons for this activity is found in the need to further enhance the geometrical design and mechanical properties of the tool design and the correct prediction methodology to fulfil industrial needs. The present state of numerical simulation capabilities in rapid die casting technologies is reviewed and the failure mode mechanisms of thermal fatigue, aimed at developing a numerical simulation with a systematic design guidance for predicting the thermal cyclic loading analysis and improvement is presented along with several other methods. The economic benefits of a numerical simulation technique in die casting are limited to tool life time, mechanical properties and design guidance. The extensive computer capabilities of a numerical simulation with a systematic design guidance methodology are exploited to provide a solution for flexible design, mechanical properties and mould life time. Related research carried out worldwide by different organisations and academic institutions are discussed.

  13. Assessment of Computer Simulation Software and Process Data for High Pressure Die Casting of Magnesium

    SciTech Connect (OSTI)

    Sabau, Adrian S; Hatfield, Edward C; Dinwiddie, Ralph Barton; Kuwana, Kazunori; Viti, Valerio; Hassan, Mohamed I; Saito, Kozo

    2007-09-01

    Computer software for the numerical simulation of solidification and mold filling is an effective design tool for cast structural automotive magnesium components. A review of commercial software capabilities and their validation procedures was conducted. Aside form the software assessment, the program addressed five main areas: lubricant degradation, lubricant application, gate atomization, and heat transfer at metal mold interfaces. A test stand for lubricant application was designed. A sensor was used for the direct measurement of heat fluxes during lubricant application and casting solidification in graphite molds. Spray experiments were conducted using pure deionized water and commercial die lubricants. The results show that the sensor can be used with confidence for measuring heat fluxes under conditions specific to the die lube application. The data on heat flux was presented in forms suitable for use in HPDC simulation software. Severe jet breakup and atomization phenomena are likely to occur due to high gate velocities in HPDC. As a result of gate atomization, droplet flow affects the mold filling pattern, air entrapment, skin formation, and ensuing defects. Warm water analogue dies were designed for obtaining experimental data on mold filling phenomena. Data on break-up jet length, break-up pattern, velocities, and droplet size distribution were obtained experimentally and was used to develop correlations for jet break-up phenomena specific to die casting gate configurations.

  14. Supplemental Immobilization Cast Stone Technology Development and Waste Form Qualification Testing Plan

    SciTech Connect (OSTI)

    Westsik, Joseph H.; Serne, R. Jeffrey; Pierce, Eric M.; Cozzi, Alex; Chung, Chul-Woo; Swanberg, David J.

    2013-05-31

    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). The pretreatment facility will have the capacity to separate all of the tank wastes into the HLW and LAW fractions, and the HLW Vitrification Facility will have the capacity to vitrify all of the HLW. However, a second immobilization facility will be needed for the expected volume of LAW requiring immobilization. A number of alternatives, including Cast Stone—a cementitious waste form—are being considered to provide the additional LAW immobilization capacity.

  15. Glass rupture disk

    DOE Patents [OSTI]

    Glass, S. Jill; Nicolaysen, Scott D.; Beauchamp, Edwin K.

    2002-01-01

    A frangible rupture disk and mounting apparatus for use in blocking fluid flow, generally in a fluid conducting conduit such as a well casing, a well tubing string or other conduits within subterranean boreholes. The disk can also be utilized in above-surface pipes or tanks where temporary and controllable fluid blockage is required. The frangible rupture disk is made from a pre-stressed glass with controllable rupture properties wherein the strength distribution has a standard deviation less than approximately 5% from the mean strength. The frangible rupture disk has controllable operating pressures and rupture pressures.

  16. Compositional threshold for Nuclear Waste Glass Durability

    SciTech Connect (OSTI)

    Kruger, Albert A.; Farooqi, Rahmatullah; Hrma, Pavel R.

    2013-04-24

    Within the composition space of glasses, a distinct threshold appears to exist that separates "good" glasses, i.e., those which are sufficiently durable, from "bad" glasses of a low durability. The objective of our research is to clarify the origin of this threshold by exploring the relationship between glass composition, glass structure and chemical durability around the threshold region.

  17. Method for heating a glass sheet

    DOE Patents [OSTI]

    Boaz, Premakaran Tucker (Livonia, MI)

    1998-01-01

    A method for heating a glass sheet includes the steps of heating a glass sheet to a first predetermined temperature and applying microwave energy to the glass sheet to heat the glass sheet to at least a second predetermined temperature to allow the glass sheet to be formed.

  18. Method for heating a glass sheet

    DOE Patents [OSTI]

    Boaz, P.T.

    1998-07-21

    A method for heating a glass sheet includes the steps of heating a glass sheet to a first predetermined temperature and applying microwave energy to the glass sheet to heat the glass sheet to at least a second predetermined temperature to allow the glass sheet to be formed. 5 figs.

  19. Control of high level radioactive waste-glass melters

    SciTech Connect (OSTI)

    Bickford, D.F.; Choi, A.S.

    1991-01-01

    Slurry Fed Melters (SFM) are being developed in the United States, Europe and Japan for the conversion of high-level radioactive waste to borosilicate glass for permanent disposal. The high transition metal, noble metal, nitrate, organic, and sulfate contents of these wastes lead to unique melter redox control requirements. Pilot waste-glass melter operations have indicated the possibility of nickel sulfide or noble-metal fission-product accumulation on melter floors, which can lead to distortion of electric heating patterns, and decrease melter life. Sulfide formation is prevented by control of the redox chemistry of the melter feed. The redox state of waste-glass melters is determined by balance between the reducing potential of organic compounds in the feed, and the oxidizing potential of gases above the melt, and nitrates and polyvalent elements in the waste. Semiquantitative models predicting limitations of organic content have been developed based on crucible testing. Computerized thermodynamic computations are being developed to predict the sequence and products of redox reactions and is assessing process variations. Continuous melter test results have been compared to improved computer staged-thermodynamic-models of redox behavior. Feed chemistry control to prevent sulfide and moderate noble metal accumulations are discussed. 17 refs., 3 figs.

  20. Advanced Lost Foam Casting Technology - Phase V

    SciTech Connect (OSTI)

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

    2004-04-29

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

  1. POROUS WALL, HOLLOW GLASS MICROSPHERES

    SciTech Connect (OSTI)

    Sexton, W.

    2012-06-30

    Hollow Glass Microspheres (HGM) is not a new technology. All one has to do is go to the internet and Google{trademark} HGM. Anyone can buy HGM and they have a wide variety of uses. HGM are usually between 1 to 100 microns in diameter, although their size can range from 100 nanometers to 5 millimeters in diameter. HGM are used as lightweight filler in composite materials such as syntactic foam and lightweight concrete. In 1968 a patent was issued to W. Beck of the 3M{trademark} Company for 'Glass Bubbles Prepared by Reheating Solid Glass Particles'. In 1983 P. Howell was issued a patent for 'Glass Bubbles of Increased Collapse Strength' and in 1988 H. Marshall was issued a patent for 'Glass Microbubbles'. Now Google{trademark}, Porous Wall, Hollow Glass Microspheres (PW-HGMs), the key words here are Porous Wall. Almost every article has its beginning with the research done at the Savannah River National Laboratory (SRNL). The Savannah River Site (SRS) where SRNL is located has a long and successful history of working with hydrogen and its isotopes for national security, energy, waste management and environmental remediation applications. This includes more than 30 years of experience developing, processing, and implementing special ceramics, including glasses for a variety of Department of Energy (DOE) missions. In the case of glasses, SRS and SRNL have been involved in both the science and engineering of vitreous or glass based systems. As a part of this glass experience and expertise, SRNL has developed a number of niches in the glass arena, one of which is the development of porous glass systems for a variety of applications. These porous glass systems include sol gel glasses, which include both xerogels and aerogels, as well as phase separated glass compositions, that can be subsequently treated to produce another unique type of porosity within the glass forms. The porous glasses can increase the surface area compared to 'normal glasses of a 1 to 2 order of

  2. Energy Saving Melting andRevert Reduction Technology (E0SMARRT): Predicting Pattern Tooling and Casting Dimension for Investment Casting

    SciTech Connect (OSTI)

    Nick Cannell; Dr. Mark Samonds; Adi Sholapurwalla; Sam Scott

    2008-11-21

    The investment casting process is an expendable mold process where wax patterns of the part and rigging are molded, assembled, shelled and melted to produce a ceramic mold matching the shape of the component to be cast. Investment casting is an important manufacturing method for critical parts because of the ability to maintain dimensional shape and tolerances. However, these tolerances can be easily exceeded if the molding components do not maintain their individual shapes well. In the investment casting process there are several opportunities for the final casting shape to not maintain the intended size and shape, such as shrinkage of the wax in the injection tool, the modification of the shape during shell heating, and with the thermal shrink and distortion in the casting process. Studies have been completed to look at the casting and shell distortions through the process in earlier phases of this project. Dr. Adrian Sabau at Oak Ridge National Labs performed characterizations and validations of 17-4 PH stainless steel in primarily fused silica shell systems with good agreement between analysis results and experimental data. Further tasks provided material property measurements of wax and methodology for employing a viscoelastic definition of wax materials into software. The final set of tasks involved the implementation of the findings into the commercial casting analysis software ProCAST, owned and maintained by ESI Group. This included: o the transfer of the wax material property data from its raw form into separate temperature-dependent thermophysical and mechanical property datasets o adding this wax material property data into an easily viewable and modifiable user interface within the pre-processing application of the ProCAST suite, namely PreCAST o and validating the data and viscoelastic wax model with respect to experimental results

  3. Casting Porosity-Free Grain Refined Magnesium Alloys

    SciTech Connect (OSTI)

    Schwam, David

    2013-08-12

    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. 

  4. Apparatus And Method For Producing Single Crystal Metallic Objects

    DOE Patents [OSTI]

    Huang, Shyh-Chin; Gigliotti, Jr., Michael Francis X.; Rutkowski, Stephen Francis; Petterson, Roger John; Svec, Paul Steven

    2006-03-14

    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.

  5. Tensile-property characterization of thermally aged cast stainless steels

    SciTech Connect (OSTI)

    Michaud, W.F.; Toben, P.T.; Soppet, W.K.; Chopra, O.K.

    1994-02-01

    The effect of thermal aging on tensile properties of cast stainless steels during service in light water reactors has been evaluated. Tensile data for several experimental and commercial heats of cast stainless steels are presented. Thermal aging increases the tensile strength of these steels. The high-C Mo-bearing CF-8M steels are more susceptible to thermal aging than the Mo-free CF-3 or CF-8 steels. A procedure and correlations are presented for predicting the change in tensile flow and yield stresses and engineering stress-vs.-strain curve of cast stainless steel as a function of time and temperature of service. The tensile properties of aged cast stainless steel are estimated from known material information, i.e., chemical composition and the initial tensile strength of the steel. The correlations described in this report may be used for assessing thermal embrittlement of cast stainless steel components.

  6. Grain Refinement of Permanent Mold Cast Copper Base Alloys

    SciTech Connect (OSTI)

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

    2005-04-01

    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.

  7. Isuzu Glass Co Ltd | Open Energy Information

    Open Energy Info (EERE)

    Glass Co Ltd Jump to: navigation, search Name: Isuzu Glass Co Ltd Place: Osaka, Osaka, Japan Zip: 557-0063 Product: Japan-based manufacturer of glass products such as Fresnel lens...

  8. 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,...

  9. 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

    2013-12-13

    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.

  10. Method of determining glass durability

    DOE Patents [OSTI]

    Jantzen, Carol Maryanne; Pickett, John Butler; Brown, Kevin George; Edwards, Thomas Barry

    1998-01-01

    A process for determining one or more leachate concentrations of one or more components of a glass composition in an aqueous solution of the glass composition by identifying the components of the glass composition, including associated oxides, determining a preliminary glass dissolution estimator, .DELTA.G.sub.p, based upon the free energies of hydration for the component reactant species, determining an accelerated glass dissolution function, .DELTA.G.sub.a, based upon the free energy associated with weak acid dissociation, .DELTA.G.sub.a.sup.WA, and accelerated matrix dissolution at high pH, .DELTA.G.sub.a.sup.SB associated with solution strong base formation, and determining a final hydration free energy, .DELTA.G.sub.f. This final hydration free energy is then used to determine leachate concentrations for elements of interest using a regression analysis and the formula log.sub.10 (N C.sub.i (g/L))=a.sub.i +b.sub.i .DELTA.G.sub.f. The present invention also includes a method to determine whether a particular glass to be produced will be homogeneous or phase separated. The present invention is also directed to methods of monitoring and controlling processes for making glass using these determinations to modify the feedstock materials until a desired glass durability and homogeneity is obtained.

  11. Holder for rotating glass body

    DOE Patents [OSTI]

    Kolleck, Floyd W.

    1978-04-04

    A device is provided for holding and centering a rotating glass body such as a rod or tube. The device includes a tubular tip holder which may be held in a lathe chuck. The device can utilize a variety of centering tips each adapted for a particular configuration, such as a glass O-ring joint or semi-ball joint.

  12. Method of determining glass durability

    DOE Patents [OSTI]

    Jantzen, C.M.; Pickett, J.B.; Brown, K.G.; Edwards, T.B.

    1998-12-08

    A process is described for determining one or more leachate concentrations of one or more components of a glass composition in an aqueous solution of the glass composition by identifying the components of the glass composition, including associated oxides, determining a preliminary glass dissolution estimator, {Delta}G{sub p}, based upon the free energies of hydration for the component reactant species, determining an accelerated glass dissolution function, {Delta}G{sub a}, based upon the free energy associated with weak acid dissociation, {Delta}G{sub a}{sup WA}, and accelerated matrix dissolution at high pH, {Delta}G{sub a}{sup SB} associated with solution strong base formation, and determining a final hydration free energy, {Delta}G{sub f}. This final hydration free energy is then used to determine leachate concentrations for elements of interest using a regression analysis and the formula log{sub 10}(N C{sub i}(g/L))=a{sub i} + b{sub i}{Delta}G{sub f}. The present invention also includes a method to determine whether a particular glass to be produced will be homogeneous or phase separated. The present invention is also directed to methods of monitoring and controlling processes for making glass using these determinations to modify the feedstock materials until a desired glass durability and homogeneity is obtained. 4 figs.

  13. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

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

    2013-10-02

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium

  14. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

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

    2013-09-17

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium

  15. Cast Stone Formulation At Higher Sodium Concentrations

    SciTech Connect (OSTI)

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

    2014-02-28

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium

  16. Methods and apparatuses for manufacturing geometric multicrystalline cast silicon and geometric multicrystalline cast silicon bodies for photovoltaics

    DOE Patents [OSTI]

    Stoddard, Nathan G

    2015-02-10

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of geometrically ordered multi-crystalline silicon 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 is provided.

  17. Epsilon Metal Waste Form for Immobilization of Noble Metals from Used Nuclear Fuel

    SciTech Connect (OSTI)

    Crum, Jarrod V.; Strachan, Denis M.; Rohatgi, Aashish; Zumhoff, Mac R.

    2013-10-01

    Epsilon metal (?-metal), an alloy of Mo, Pd, Rh, Ru, and Tc, is being developed as a waste form to treat and immobilize the undissolved solids and dissolved noble metals from aqueous reprocessing of commercial used nuclear fuel. Epsilon metal is an attractive waste form for several reasons: increased durability relative to borosilicate glass, it can be fabricated without additives (100% waste loading), and in addition it also benefits borosilicate glass waste loading by eliminating noble metals from the glass and thus the processing problems related there insolubility in glass. This work focused on the processing aspects of the epsilon metal waste form development. Epsilon metal is comprised of refractory metals resulting in high reaction temperatures to form the alloy, expected to be 1500 - 2000C making it a non-trivial phase to fabricate by traditional methods. Three commercially available advanced technologies were identified: spark-plasma sintering, microwave sintering, and hot isostatic pressing, and investigated as potential methods to fabricate this waste form. Results of these investigations are reported and compared in terms of bulk density, phase assemblage (X-ray diffraction and elemental analysis), and microstructure (scanning electron microscopy).

  18. Functionally Graded Materials for Manufacturing Tools and Dies...

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

    New Material Processes Improve the Performance and Lifetime of Tools and Dies Tools, dies, and process equipment currently used in the metal casting, forging, and glass ...

  19. A New Direct-Pour In-Mold (DPI) Technology for Producing Ductile and Compacted Graphite Iron Castings.

    SciTech Connect (OSTI)

    Jason Hitchings; Jay R. Hitchings

    2007-07-20

    A new "Direct Pour In-Mold" (DPI) Magnesium treatment technology has been developed that can produce both Nodular and Compacted Graphite iron. The DPI technology converts the standard horizontal runner system into a vertical one, by placing a Magnesium Ferrosilicon treatment alloy and molten metal filter into a specially designed container. The DPI container is easily placed into either vertically or horizontally parted molds, and then a base metal can be poured directly into it. The metal is treated and filtered as it passes through, and then proceeds directly into a runner or casting cavity. Various sizes of containers provide all of the necessary components required to deliver a range of weights of treated and filtered metal at accurate and consistent flow rates. The DPI containers provide energy savings over competing techniques, increased mold yields, very high Magnesium recovery, zero Magnesium fume, and no post inoculation is required. By treating the metal just prior to it entering a casting cavity many other benefits and advantages are also realized.

  20. Lead phosphate glass compositions for optical components

    DOE Patents [OSTI]

    Sales, Brian C.; Boatner, Lynn A.

    1987-01-01

    A lead phosphate glass to which has been added indium oxide or scandium oe to improve chemical durability and provide a lead phosphate glass with good optical properties.

  1. ^Rhenium solubility in HLW glasses-05072012 (1)

    Office of Scientific and Technical Information (OSTI)

    into high-volume low-activity waste (LAW) and ... melts exhibited different physical and chemical features ... test method for measuring waste glass or glass ...

  2. Method for fabricating transistors using crystalline silicon devices on glass

    DOE Patents [OSTI]

    McCarthy, A.M.

    1997-09-02

    A method for fabricating transistors using single-crystal silicon devices on glass. This method overcomes the potential damage that may be caused to the device during high voltage bonding and employs a metal layer which may be incorporated as part of the transistor. This is accomplished such that when the bonding of the silicon wafer or substrate to the glass substrate is performed, the voltage and current pass through areas where transistors will not be fabricated. After removal of the silicon substrate, further metal may be deposited to form electrical contact or add functionality to the devices. By this method both single and gate-all-around devices may be formed. 13 figs.

  3. CENTER FOR ADVANCED SEPARATION TECHNOLOGY (CAST) PROGRAM

    SciTech Connect (OSTI)

    Yoon, Roe-Hoan; Hull, Christopher

    2014-09-30

    The U.S. is the largest producer of mining products in the world. In 2011, U.S. mining operations contributed a total of $232 billion to the nation’s GDP plus $138 billion in labor income. Of this the coal mining industry contributed a total of $97.5 billion to GDP plus $53 billion in labor income. Despite these contributions, the industry has not been well supported with research and development funds as compared to mining industries in other countries. To overcome this problem, the Center for Advanced Separation Technologies (CAST) was established to develop technologies that can be used by the U.S. mining industry to create new products, reduce production costs, and meet environmental regulations.

  4. Method of casting silicon into thin sheets

    DOE Patents [OSTI]

    Sanjurjo, Angel; Rowcliffe, David J.; Bartlett, Robert W.

    1982-10-26

    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.

  5. Irradiation response of delta ferrite in as-cast and thermally aged cast stainless steel

    SciTech Connect (OSTI)

    Li, Zhangbo; Lo, Wei-Yang; Chen, Yiren; Pakarinen, Janne; Wu, Yaqiao; Allen, Todd; Yang, Yong

    2015-08-08

    To enable the life extension of Light Water Reactors (LWRs) beyond 60 years, it is critical to gain adequate knowledge for making conclusive predictions to assure the integrity of duplex stainless steel reactor components, e.g. primary pressure boundary and reactor vessel internal. Microstructural changes in the ferrite of thermally aged, neutron irradiated only, and neutron irradiated after being thermally aged cast austenitic stainless steels (CASS) were investigated using atom probe tomography. The thermal aging was performed at 400 °C for 10,000 h and the irradiation was conducted in the Halden reactor at ~315 °C to 0.08 dpa (5.6 × 1019 n/cm2 E > 1 MeV). Low dose neutron irradiation at a dose rate of 5 × 10-9 dpa/s was found to induce spinod,al decomposition in the ferrite of as-cast microstructure, and further to enhance the spinodal decomposition in the thermally aged cast alloys. Regarding the G-phase precipitates, the neutron irradiation dramatically increases the precipitate size, and alters the composition of the precipitates with increased, Mn, Ni, Si and Mo and reduced Fe and Cr contents. Lastly, The results have shown that low dose neutron irradiation can further accelerate the degradation of ferrite in a duplex stainless steel at the LWR relevant condition.

  6. Irradiation response of delta ferrite in as-cast and thermally aged cast stainless steel

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

    Li, Zhangbo; Lo, Wei-Yang; Chen, Yiren; Pakarinen, Janne; Wu, Yaqiao; Allen, Todd; Yang, Yong

    2015-08-08

    To enable the life extension of Light Water Reactors (LWRs) beyond 60 years, it is critical to gain adequate knowledge for making conclusive predictions to assure the integrity of duplex stainless steel reactor components, e.g. primary pressure boundary and reactor vessel internal. Microstructural changes in the ferrite of thermally aged, neutron irradiated only, and neutron irradiated after being thermally aged cast austenitic stainless steels (CASS) were investigated using atom probe tomography. The thermal aging was performed at 400 °C for 10,000 h and the irradiation was conducted in the Halden reactor at ~315 °C to 0.08 dpa (5.6 × 1019more » n/cm2 E > 1 MeV). Low dose neutron irradiation at a dose rate of 5 × 10-9 dpa/s was found to induce spinod,al decomposition in the ferrite of as-cast microstructure, and further to enhance the spinodal decomposition in the thermally aged cast alloys. Regarding the G-phase precipitates, the neutron irradiation dramatically increases the precipitate size, and alters the composition of the precipitates with increased, Mn, Ni, Si and Mo and reduced Fe and Cr contents. Lastly, The results have shown that low dose neutron irradiation can further accelerate the degradation of ferrite in a duplex stainless steel at the LWR relevant condition.« less

  7. Hollow microspheres of silica glass and method of manufacture

    DOE Patents [OSTI]

    Downs, Raymond L.; Miller, Wayne J.

    1982-01-01

    A method of manufacturing gel powder suitable for use as a starting material in the manufacture of hollow glass microspheres having a high concentration of silica. The powder is manufactured from a gel containing boron in the amount of about 1% to 20% (oxide equivalent mole percent), alkali metals, specifically potassium and sodium, in an amount exceeding 8% total, and the remainder silicon. Preferably, the ratio of potassium to sodium is greater than 1.5.

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

    DOE Patents [OSTI]

    Praeg, W.F.

    1997-02-11

    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.

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

    DOE Patents [OSTI]

    Praeg, Walter F.

    1997-01-01

    An apparatus 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.

  10. Apparatus for efficient sidewall containment of molten metal with horizontal alternating magnetic fields utilizing low reluctance rims

    DOE Patents [OSTI]

    Praeg, Walter F.

    1999-01-01

    A method and apparatus 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 rollers including low reluctance rim structures. The magnetic field and the rollers help contain the molten metal from leaking out of the containment structure.

  11. Development of a thin steel strip casting process. Final report

    SciTech Connect (OSTI)

    Williams, R.S.

    1994-04-01

    This is a comprehensive effort to develop direct strip casting to the point where a pilot scale program for casting carbon steel strip could be initiated. All important aspects of the technology were being investigated, however the program was terminated early due to a change in the business strategy of the primary contractor, Armco Inc. (focus to be directed at specialty steels, not low carbon steel). At termination, the project was on target on all milestones and under budget. Major part was casting of strip at the experiment casting facility. A new caster, capable of producing direct cast strip of up to 12 in. wide in heats of 1000 and 3000 lb, was used. A total of 81 1000-1200 lb heats were cast as well as one test heat of 3000 lb. Most produced strip of from 0.016 to 0.085 in. thick. Process reliability was excellent for short casting times; quality was generally poor from modern hot strip mill standards, but the practices necessary for good surface quality were identified.

  12. Glass ceramic seals to inconel

    DOE Patents [OSTI]

    McCollister, Howard L.; Reed, Scott T.

    1983-11-08

    A glass ceramic composition prepared by subjecting a glass composition comprising, by weight, 65-80% SiO.sub.2, 8-16%, Li.sub.2 O, 2-8% , Al.sub.2 O.sub.3, 1-8% K.sub.2 O, 1-5% P.sub.2 O.sub.5 and 1.5-7% B.sub.2 O.sub.3, to the following processing steps of heating the glass composition to a temperature sufficient to crystallize lithium metasilicate therein, holding the glass composition at a temperature and for a time period sufficient to dissolve the lithium metasilicate therein thereby creating cristobalite nucleii, cooling the glass composition and maintaining the composition at a temperature and for a time period sufficient to recrystallize lithium metasilicate therein, and thermally treating the glass composition at a temperature and for a time period sufficient to cause growth of cristobalite and further crystallization of lithium metasilicate producing a glass ceramic composition having a specific thermal expansion coefficient and products containing said composition.

  13. Method of handling radioactive alkali metal waste

    DOE Patents [OSTI]

    Wolson, Raymond D.; McPheeters, Charles C.

    1980-01-01

    Radioactive alkali metal is mixed with particulate silica in a rotary drum reactor in which the alkali metal is converted to the monoxide during rotation of the reactor to produce particulate silica coated with the alkali metal monoxide suitable as a feed material to make a glass for storing radioactive material. Silica particles, the majority of which pass through a 95 mesh screen or preferably through a 200 mesh screen, are employed in this process, and the preferred weight ratio of silica to alkali metal is 7 to 1 in order to produce a feed material for the final glass product having a silica to alkali metal monoxide ratio of about 5 to 1.

  14. Method of handling radioactive alkali metal waste

    DOE Patents [OSTI]

    Wolson, R.D.; McPheeters, C.C.

    Radioactive alkali metal is mixed with particulate silica in a rotary drum reactor in which the alkali metal is converted to the monoxide during rotation of the reactor to produce particulate silica coated with the alkali metal monoxide suitable as a feed material to make a glass for storing radioactive material. Silica particles, the majority of which pass through a 95 mesh screen or preferably through a 200 mesh screen, are employed in this process, and the preferred weight ratio of silica to alkali metal is 7 to 1 in order to produce a feed material for the final glass product having a silica to alkali metal monoxide ratio of about 5 to 1.

  15. Process for casting hard-faced, lightweight camshafts and other cylindrical products

    DOE Patents [OSTI]

    Hansen, Jeffrey S.; Turner, Paul C.; Argetsinger, Edward R.; Wilson, Rick D.

    1996-01-01

    A process for casting a hard-faced cylindrical product such as an automobile camshaft includes the steps of: (a) preparing a composition formed from a molten base metal and an additive in particle form and having a hardness value greater than the hardness value of the base metal; (b) introducing the composition into a flask containing a meltable pattern of a cylindrical product such as an automobile camshaft to be manufactured and encased in sand to allow the composition to melt the pattern and assume the shape of the pattern within the sand; and (c) rotating the flask containing the pattern about the longitudinal axes of both the flask and the pattern as the molten base metal containing the additive in particle form is introduced into the flask to cause particles of the additive entrained in the molten base metal to migrate by centrifugal action to the radial extremities of the pattern and thereby provide a cylindrical product having a hardness value greater at it's radial extremities than at its center when the molten base metal solidifies.

  16. Predicting Pattern Tooling and Casting Dimensions for Investment Casting, Phase III

    SciTech Connect (OSTI)

    Sabau, Adrian S

    2008-04-01

    Efforts during Phase III focused mainly on the shell-alloy systems. A high melting point alloy, 17-4PH stainless steel, was 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. Shell molds made of fused-silica and alumino-silicates were considered. A literature review was conducted on thermophysical and thermomechanical properties alumino-silicates. Material property data, which were not available from material suppliers, was obtained. For all the properties of 17-4PH stainless steel, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. Thus, some material properties were evaluated using ProCAST, based on CompuTherm database. A comparison between the predicted material property data and measured property data was made. It was found that most material properties were accurately predicted only over several temperature ranges. No experimental data for plastic modulus were found. Thus, several assumptions were made and ProCAST recommendations were followed in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted during heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution on heating and cooling. Numerical simulations were performed using ProCAST for the investment casting of 17-4PH stainless steel parts in fused silica molds using the thermal expansion obtained on heating and another one with thermal expansion obtained on cooling. 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 shell mold was considered to be a pure elastic material. The alloy dimensions were

  17. Phosphate glass useful in high power lasers

    DOE Patents [OSTI]

    Hayden, J.S.; Sapak, D.L.; Ward, J.M.

    1990-05-29

    A low- or no-silica phosphate glass useful as a laser medium and having a high thermal conductivity, K[sub 90 C] > 0.8 W/mK, and a low coefficient of thermal expansion, [alpha][sub 20--40 C] < 80[times]10[sup [minus]7]/C, consists essentially of (on a batch composition basis Mole %): P[sub 2]O[sub 5], 45-70; Li[sub 2]O, 15-35; Na[sub 2]O, 0-10; Al[sub 2]O[sub 3], 10-15; Nd[sub 2]O[sub 3], 0.01-6; La[sub 2]O[sub 3], 0-6; SiO[sub 2], 0-8; B[sub 2]O[sub 3], 0-8; MgO, 0-18; CaO, 0-15; SrO, 0-9; BaO, 0-9; ZnO, 0-15; the amounts of Li[sub 2]O and Na[sub 2]O providing an average alkali metal ionic radius sufficiently low whereby said glass has K[sub 90 C] > 0.8 W/mK and [alpha][sub 20--40 C] < 80[times]10[sup [minus]7]/C, and wherein, when the batch composition is melted in contact with a silica-containing surface, the final glass composition contains at most about 3.5 mole % of additional silica derived from such contact during melting. The Nd[sub 2]O[sub 3] can be replaced by other lasing species. 3 figs.

  18. Method for manufacturing glass frit

    DOE Patents [OSTI]

    Budrick, Ronald G.; King, Frank T.; Nolen, Jr., Robert L.; Solomon, David E.

    1977-01-01

    A method of manufacturing a glass frit for use in the manufacture of uniform glass microspheres to serve as containers for laser fusion fuel to be exposed to laser energy which includes the formation of a glass gel which is then dried, pulverized, and very accurately sized to particles in a range of, for example, 125 to 149 micrometers. The particles contain an occluded material such as urea which expands when heated. The sized particles are washed, dried, and subjected to heat to control the moisture content prior to being introduced into a system to form microspheres.

  19. Shrinkage Prediction for the Investment Casting of Stainless Steels

    SciTech Connect (OSTI)

    Sabau, Adrian S [ORNL

    2007-01-01

    In this study, the alloy shrinkage factors were obtained for the investment casting of 17-4PH stainless steel parts. For the investment casting process, unfilled wax and fused silica with a zircon prime coat were used for patterns and shell molds, respectively. Dimensions of the die tooling, wax pattern, and casting were measured using a Coordinate Measurement Machine in order to obtain the actual tooling allowances. The alloy dimensions were obtained from numerical simulation results of solidification, heat transfer, and deformation phenomena. The numerical simulation results for the shrinkage factors were compared with experimental results.

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

    SciTech Connect (OSTI)

    Kim, Young

    2013-08-20

    Cast Stone is undergoing evaluation as the supplemental treatment technology for Hanford’s (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.