Heavy metals processing near-net-forming summary progress report
- Custom Spray Technologies, Inc., Rigby, ID (United States)
- Martin Marietta Energy Systems, Inc., Oak Ridge, TN (United States)
This study utilized a converging-diverging nozzle to spray-form an alloy having a weight percent composition of 49.6% iron, 49.6% tungsten, and 0.8% carbon into samples for analysis. The alloy was a surrogate that displayed metallurgical characteristics similar to the alloys used in the heavy metals processing industry. US DOE facilities are evaluating advanced technologies which can simplify component fabrication, reduce handling steps, and minimize final machining. The goal of producing net-shaped components can be approached from several directions. In spray forming, molten metal is converted by a nozzle into a plume of fine droplets which quickly cool in flight and solidify against a substrate. The near-final dimension product that is formed receives additional benefits from rapid solidification. This single-step processing approach would aid the heavy metals industry by streamlining fabrication, improving production yields, and minimizing the generation of processing wastes. This Program effort provided a large selection of as-sprayed specimens. These samples were sprayed with gas-to-metal mass ratios ranging from 0.8:1 to 4:1. Samples targeted for analysis were produced from different spray conditions. Metallography on some samples revealed areas that were fully dense and homogeneous at 5,000X. These areas averaged grain sizes of 1 micron diameter. Other samples when viewed at 2,000X were highly segregated in the 10 micron diameter range. Deposit efficiencies of greater than 90% were demonstrated using the untailored spray system. Discharge gases were analyzed and two categories of particles were identified. One category of particle had a chemical composition characteristic of the alloy being sprayed and the second type of particle had a chemical composition characteristic of the ceramics used in the spray system component fabrication. Particles ranged in size from 0.07 to 3 microns in diameter. 8 refs., 67 figs., 20 tabs.
- Research Organization:
- Oak Ridge Y-12 Plant (Y-12), Oak Ridge, TN (United States); Custom Spray Technologies, Inc., Rigby, ID (United States)
- Sponsoring Organization:
- USDOE, Washington, DC (United States)
- DOE Contract Number:
- AC05-84OR21400
- OSTI ID:
- 132677
- Report Number(s):
- Y/SUB-94GSK39V/1; CST-2734; ON: DE96002329; TRN: AHC29529%%39
- Resource Relation:
- Other Information: PBD: Sep 1994
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
IRON ALLOYS
SPRAY COATING
TUNGSTEN ALLOYS
CARBON STEELS
SPRAYED COATINGS
GRAPHITE
MATERIALS HANDLING EQUIPMENT
PERFORMANCE
PROGRESS REPORT
CARBON ADDITIONS
LIQUID METALS
METAL INDUSTRY
PARTICLE SIZE
MINIMIZATION
INDUSTRIAL WASTES
TUBES
RODS
PLATES
EXPERIMENTAL DATA