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Title: In-service testing of Ni{sub 3}Al coupons and trays in carburizing furnaces at Delphi Saginaw. CRADA final report

Abstract

This Cooperative Research and Development Agreement (CRADA) report deals with the development of nickel aluminide alloy for improved longer life heat-resistant fixture assemblies for batch and continuous pusher carburizing furnaces. The nickel aluminide development was compared in both coupon and component testing with the currently used Fe-Ni-Cr heat-resisting alloy known as HU. The specific goals of the CRADA were: (1) casting process development, (2) characterization and possible modification of the alloy composition to optimize its manufacturing ability and performance under typical furnace operating conditions, and (3) testing and evaluation of specimens and prototype fixtures. In support of the CRADA objectives, coupons of nickel aluminide and the HU alloy were installed in both batch and pusher furnaces. The coupons were taken from two silicon levels and contained welds made with two different filler compositions (IC-221LA and IC-221W). Both nickel-aluminide and HU coupons were removed from the batch and pusher carburizing furnace at time intervals ranging from one month to one year. The exposed coupons were cut and mounted for metallographic, hardness, and microprobe analysis. The results of the microstructural analysis have been transmitted to General Motors Corporation, Saginaw Division (Delphi Saginaw) through reports that were presented at periodic CRADA review meetings.more » Based on coupon testing and verification of the coupon results with the testing of trays, Delphi Saginaw moved forward with the use of six additional trays in a batch furnace and two assemblies in a pusher furnace. Fifty percent of the trays and fixtures are in the as-cast condition and the remaining trays and fixtures are in the preoxidized condition. The successful operating experience of two assemblies in the pusher furnace for nearly a year formed the basis for a production run of 63 more assemblies. The production run required melting of 94 heats weighing 500 lb. each. Twenty-six of the 94 heats were from virgin stock, and 68 were from the revert that used 50% virgin and 50% revert. Detailed chemical analysis of the 94 heats reflected that the nickel aluminide can be cast into heat-treat fixtures under production conditions. In addition to the chemical analysis, the castings showed excellent dimensional reproducibility. A total of six batch furnace trays and 65 pusher furnace assemblies of nickel aluminide alloy IC-221M are currently operating in production furnaces at Delphi Saginaw. Two of the pusher furnace assemblies have completed two years of service without any failure. The CRADA has accomplished the goal of demonstrating that the nickel aluminide can be produced under commercial production conditions and it has superior performance over the currently used HU alloy in both batch and pusher furnaces.« less

Authors:
; ; ;  [1];  [2]
  1. Oak Ridge National Lab., TN (United States)
  2. General Motors Corporaion, Saginaw Division (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab., TN (United States)
Sponsoring Org.:
USDOE Assistant Secretary for Energy Efficiency and Renewable Energy, Washington, DC (United States)
OSTI Identifier:
310024
Report Number(s):
ORNL/M-6592
ON: DE99000312; CRN: C/ORNL 92-0076
DOE Contract Number:  
AC05-96OR22464
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: Aug 1998
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; CARBURIZATION; NICKEL ALLOYS; ALUMINIUM ALLOYS; FURNACES; MATERIALS TESTING

Citation Formats

Sikka, V.K., Santella, M.L., Viswanathan, S., Swindeman, R.W., and Chatterjee, M. In-service testing of Ni{sub 3}Al coupons and trays in carburizing furnaces at Delphi Saginaw. CRADA final report. United States: N. p., 1998. Web. doi:10.2172/310024.
Sikka, V.K., Santella, M.L., Viswanathan, S., Swindeman, R.W., & Chatterjee, M. In-service testing of Ni{sub 3}Al coupons and trays in carburizing furnaces at Delphi Saginaw. CRADA final report. United States. doi:10.2172/310024.
Sikka, V.K., Santella, M.L., Viswanathan, S., Swindeman, R.W., and Chatterjee, M. Sat . "In-service testing of Ni{sub 3}Al coupons and trays in carburizing furnaces at Delphi Saginaw. CRADA final report". United States. doi:10.2172/310024. https://www.osti.gov/servlets/purl/310024.
@article{osti_310024,
title = {In-service testing of Ni{sub 3}Al coupons and trays in carburizing furnaces at Delphi Saginaw. CRADA final report},
author = {Sikka, V.K. and Santella, M.L. and Viswanathan, S. and Swindeman, R.W. and Chatterjee, M.},
abstractNote = {This Cooperative Research and Development Agreement (CRADA) report deals with the development of nickel aluminide alloy for improved longer life heat-resistant fixture assemblies for batch and continuous pusher carburizing furnaces. The nickel aluminide development was compared in both coupon and component testing with the currently used Fe-Ni-Cr heat-resisting alloy known as HU. The specific goals of the CRADA were: (1) casting process development, (2) characterization and possible modification of the alloy composition to optimize its manufacturing ability and performance under typical furnace operating conditions, and (3) testing and evaluation of specimens and prototype fixtures. In support of the CRADA objectives, coupons of nickel aluminide and the HU alloy were installed in both batch and pusher furnaces. The coupons were taken from two silicon levels and contained welds made with two different filler compositions (IC-221LA and IC-221W). Both nickel-aluminide and HU coupons were removed from the batch and pusher carburizing furnace at time intervals ranging from one month to one year. The exposed coupons were cut and mounted for metallographic, hardness, and microprobe analysis. The results of the microstructural analysis have been transmitted to General Motors Corporation, Saginaw Division (Delphi Saginaw) through reports that were presented at periodic CRADA review meetings. Based on coupon testing and verification of the coupon results with the testing of trays, Delphi Saginaw moved forward with the use of six additional trays in a batch furnace and two assemblies in a pusher furnace. Fifty percent of the trays and fixtures are in the as-cast condition and the remaining trays and fixtures are in the preoxidized condition. The successful operating experience of two assemblies in the pusher furnace for nearly a year formed the basis for a production run of 63 more assemblies. The production run required melting of 94 heats weighing 500 lb. each. Twenty-six of the 94 heats were from virgin stock, and 68 were from the revert that used 50% virgin and 50% revert. Detailed chemical analysis of the 94 heats reflected that the nickel aluminide can be cast into heat-treat fixtures under production conditions. In addition to the chemical analysis, the castings showed excellent dimensional reproducibility. A total of six batch furnace trays and 65 pusher furnace assemblies of nickel aluminide alloy IC-221M are currently operating in production furnaces at Delphi Saginaw. Two of the pusher furnace assemblies have completed two years of service without any failure. The CRADA has accomplished the goal of demonstrating that the nickel aluminide can be produced under commercial production conditions and it has superior performance over the currently used HU alloy in both batch and pusher furnaces.},
doi = {10.2172/310024},
journal = {},
number = ,
volume = ,
place = {United States},
year = {1998},
month = {8}
}