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Title: Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds

Abstract

LEU-10%Mo castings are commonly produced by down blending unalloyed HEU with a DU-12.7%Mo master-alloy. This work uses process modeling to provide insight into the mixing of the unalloyed uranium and U-Mo master alloy during melting and mold filling of a triple plate casting. Two different sets of situations are considered: (1) mixing during mold filling from a compositionally stratified crucible and (2) convective mixing of a compositionally stratified crucible during mold heating. The mold filling simulations are performed on the original Y-12 triple plate mold and the horizontal triple plate mold.

Authors:
 [1]
  1. Los Alamos National Lab. (LANL), Los Alamos, NM (United States)
Publication Date:
Research Org.:
Los Alamos National Lab. (LANL), Los Alamos, NM (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1352396
Report Number(s):
LA-UR-17-22962
DOE Contract Number:
AC52-06NA25396
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

Aikin, Jr., Robert M.. Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds. United States: N. p., 2017. Web. doi:10.2172/1352396.
Aikin, Jr., Robert M.. Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds. United States. doi:10.2172/1352396.
Aikin, Jr., Robert M.. Wed . "Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds". United States. doi:10.2172/1352396. https://www.osti.gov/servlets/purl/1352396.
@article{osti_1352396,
title = {Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds},
author = {Aikin, Jr., Robert M.},
abstractNote = {LEU-10%Mo castings are commonly produced by down blending unalloyed HEU with a DU-12.7%Mo master-alloy. This work uses process modeling to provide insight into the mixing of the unalloyed uranium and U-Mo master alloy during melting and mold filling of a triple plate casting. Two different sets of situations are considered: (1) mixing during mold filling from a compositionally stratified crucible and (2) convective mixing of a compositionally stratified crucible during mold heating. The mold filling simulations are performed on the original Y-12 triple plate mold and the horizontal triple plate mold.},
doi = {10.2172/1352396},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Wed Apr 12 00:00:00 EDT 2017},
month = {Wed Apr 12 00:00:00 EDT 2017}
}

Technical Report:

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  • This work describes the experiments and modeling that have been performed to improve and try to optimize the simultaneous casting of three plates of U-10wt%Mo in a single coil vacuum induction melting (VIM) furnace. The plates of interest are 280 mm wide by 203 mm tall by 5 mm thick (11" x 8" x 0.2"). The initial mold design and processing parameters were supplied by Y-12. The mold and casting cavity were instrumented with a number of thermocouples, and the casting performed to determine the thermal history of the mold and casting. The resulting cast plates were radiographed and numerousmore » defects identified. Metallography was performed to help identify the nature of the radiographically observed defects. This information was then used to validate a mold filling and solidification model of that casting. Based on the initial casting, good casting design practice, and process simulation of several design alternatives, a revised design was developed with the goal of minimizing casting defects such as porosity. The redesigned mold had a larger hot-top and had its long axis along the horizontal direction. These changes were to try to develop a strong thermal gradient conducive to good feeding and minimization of micro- and macroporosity in the cast plates. An instrumented casting was then performed with the revised mold design and a linear distributor. This design yielded cast plates with significantly less radiographically identified defects. Unfortunately, there was significant variation in plate weight and metal content in their hot-tops. Fluid flow simulations were then performed on this mold/distributor design. This helped identify the issue with this linear distributor design. Additional simulations were then performed on candidate distributor redesigns and a preferred distributor annular design was identified. This improved annular design was used to produce a third instrumented casting with favorable results. These refined designs and their radiographic characterization are compared to the initial design.« less
  • This report presents an overview of LANL casting procedure and characterization of recent DU U-10 Mo castings and characterizes recent LEU U-10Mo casting from Y-12.
  • The development program was carried out at the Experimental Foundry at the Abex Research Center, Mahwah, NJ. Objectives were met and data collected to design VACLAIM systems. Feasibility was established and several configurations of equipment used with success. The experiments included test and commercial castings. VACLAIM reduces foundry energy needs, materials, investment costs, operating costs, and improves foundry atmospheres and casting quality in a single step. The system is expected to be installed in 60 or more foundries in the next ten years to save up to $27 million per year in investment and processing costs.
  • 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.