Study of growth parameters for refractory carbide single crystals quarterly status report no. 4, dec. 1, 1964 - mar. 1, 1965
Growth of single crystals of tantalum carbide and hafnium carbide, and their solid solutions
SINGLE CRYSTAL↗
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Discrete element weld model, phase 2
A numerical method was developed for analyzing the tungsten inert gas (TIG) welding process. The phenomena being modeled include melting under the arc and the flow in the melt under the action of buoyancy, surface tension, and electromagnetic forces. The latter entails the calculation of the electric potential and the computation of electric current and magnetic field therefrom. Melting may occur at a single temperature or over a temperature range, and the electrical and thermal conductivities can be a function of temperature. Results of sample calculations are presented and discussed at length. A major research contribution has been the development of numerical methodology for the calculation of phase change problems in a fixed grid framework. The model has been implemented on CHAM's general purpose computer code PHOENICS. The inputs to the computer model include: geometric parameters, material properties, and weld process parameters.
Prakash, C.↗
High-temperature containerless aircraft furnace experimentation in the microgravity environment aboard a KC-135 aircraft
This paper describes a materials processing research furnace, the High-Temperature Containerless Aircraft Furnace (HITCAF), which uses an electric arc to melt and resolidify materials in the microgravity environment aboard a KC-135 aircraft. The HITCAF is designed to process almost every electrically conductive material, including such high-melting-point materials as tungsten, within a 15 to 20 sec microgravity period. It operates on tungsten/inert gas welding principles, using an adapted commercially available tube welder. The HITCAF is fully operational and available for use by researchers representing the Government agencies, as well as industry and academia.
Poorman, Richard M.↗
Surface fatigue life of M50NiL and AISI 9310 spur gears and R C bars
Spur gear endurance tests and rolling element surface fatigue tests were conducted to study vacuum induction melted, vacuum arc remelted (VIM-VAR) M50NiL steel for use as a gear steel in advanced aircraft applications, to determine its endurance characteristics, and to compare the results with those for standard VAR and VIM-VAR AISI 9310 gear material. Tests were conducted with spur gears and rolling contact bars manufactured from VIM-VAR M50NiL and VAR and VIM-VAR AISI 9310. The gear pitch diameter was 8.9 cm. Gear test conditions were an inlet oil temperature of 320 K, and outlet oil temperature of 350 K, a maximum Hertz stress of 1.71 GPa, and a speed of 10000 rpm. Bench rolling element fatigue tests were conducted at ambient temperatures with a bar speed of 12,500 rpm and a maximum Hertz stress of 4.83 GPa. The VIM-VAR M50NiL gears had a surface fatigue life that was 4.5 and 11.5 times that for VIM-VAR and VAR AISI 9310 gears, respectively. The surface fatigue life of the VIM-VAR M50NiL rolling contact bars was 13.2 and 21.6 times that for the VIM-VAR and VAR AISI 9310, respectively. The VIM-VAR M50NiL material was shown to have good resistance to fracture through a fatigue spall and superior fatigue life to both other gears.
Townsend, Dennis P.↗
Development of Non-Concentrated Alloys for Nuclear Applications
This presentation summarizes the fabrication and characterization of non-concentrated alloys for the preparation of slides for the project review meeting.
36 - MATERIALS SCIENCE↗
Determination of work functions near melting points of refractory metals by using a direct-current arc
Effective work functions of refractory metals at temperatures near their melting points were determined by using a direct-current arc. A metal wire connected as the cathode was melted by striking an arc discharge in an argon atmosphere. A melted sphere was formed with a definite emitting area which was calculated from the sphere diameter measured after terminating the arc. Effective work functions were calculated from the Richardson-Dushman equation by using this emission area. The procedure is experimentally advantageous because surface cleanliness of the specimen is not critical, high vacuum is not required, and the anode-cathode spacing is not critical.
Gordon, W. A.↗
Effect of water on the composition of partial melts of greenstone and amphibolite
Closed-system partial melts of hydrated, metamorphosed arc basalts and andesites (greenstones and amphibolites), where only water structurally bound in metamorphic minerals is available for melting (dehydration melting), are generally water-undersaturated, coexist with plagioclase-rich, anhydrous restites, and have compositions like island arc tonalites. In contrast, water-saturated melting at water pressures of 3 kilobars yields strongly peraluminous, low iron melts that coexist with an amphibole-bearing, plagioclase-poor restite. These melt compositions are unlike those of most natural silicic rocks. Thus, dehydration melting over a range of pressures in the crust of island arcs is a plausible mechanism for the petrogenesis of islands arc tonalite, whereas water-saturated melting at pressure of 3 kilobars and above is not.
Beard, James S.↗
Melting Behavior of Conventional and Hydrogen-Reduced DRI in a Simulated EAF Steel Bath
The melting behavior of carbon-free direct reduced iron (DRI) produced by hydrogen reduction has been investigated in a simulated electric arc furnace (EAF) melting environment. A testing apparatus was created to document the melting rates under various bath conditions in slag and steel. This investigation is specific to pellets melted in a steel bath. A model was developed to simulate the shell growth and melting rate of a non-reactive DRI pellet in molten steel. Data acquired from preliminary experiments are utilized to validate the model. This investigation sheds light on the potential effects of melting hydrogen-reduced DRI in the EAF.
36 MATERIALS SCIENCE↗
Effect of double vacuum melting and retained austenite on rolling-element fatigue life of AMS 5749 bearing steel
AMS 5749 steel combines the tempering, hot hardness, and hardness retention characteristics of AISI M-50 steel with the corrosion and oxidation resistance of AISI 440C stainless steel. The five-ball fatigue tester was used to evaluate the rolling-element fatigue life of AMS 5749. Double vacuum melting (vacuum induction melting plus vacuum arc remelting, VIM-VAR) produced AMS 5749 material with a rolling-element fatigue life at least 14 times that of vacuum induction melting alone. The VIM-VAR AMS 5749 steel balls gave lives from 6 to 12 times greater than VIM-VAR AISI M-50 steel balls. The highest level of retained austenite, 14.6 percent, was significantly detrimental to rolling-element fatigue life relative to the intermediate level of 11.1 percent.
Parker, R. J.↗
Oxygen isotope ratios in zircon and garnet: A record of assimilation and fractional crystallization in the Dinkey Dome peraluminous granite, Sierra Nevada, California
Abstract The 119 Ma Dinkey Dome pluton in the central Sierra Nevada Batholith is a peraluminous granite and contains magmatic garnet and zircon that are complexly zoned with respect to oxygen isotope ratios. Intracrystalline SIMS analysis tests the relative importance of magmatic differentiation processes vs. partial melting of metasedimentary rocks. Whereas δ18O values of bulk zircon concentrates are uniform across the entire pluton (7.7‰ VSMOW), zircon crystals are zoned in δ18O by up to 1.8‰, and when compared to late garnet, show evidence of changing magma chemistry during multiple interactions of the magma with wall rock during crustal transit. The evolution from an early high-δ18O magma [δ18O(WR) = 9.8‰] toward lower values is shown by high-δ18O zircon cores (7.8‰) and lower δ 18O rims (6.8‰). Garnets from the northwest side of the pluton show a final increase in δ18O with rims reaching 8.1‰. In situ REE measurements show zircon is magmatic and grew before garnets. Additionally, δ18O in garnets from the western side of the pluton are consistently higher (avg = 7.3‰) relative to the west (avg = 5.9‰). These δ18O variations in zircon and garnet record different stages of assimilation and fractional crystallization whereby an initially high-δ18O magma partially melted low-δ18O wallrock and was subsequently contaminated near the current level of emplacement by higher δ18O melts. Collectively, the comparison of δ18O zoning in garnet and zircon shows how a peraluminous pluton can be constructed from multiple batches of variably contaminated melts, especially in early stages of arc magmatism where magmas encounter significant heterogeneity of wall-rock assemblages. Collectively, peraluminous magmas in the Sierran arc are limited to small <100 km2 plutons that are intimately associated with metasedimentary wall rocks and often surrounded by later and larger metaluminous tonalite and granodiorite plutons. The general associations suggest that early-stage arc magmas sample crustal heterogeneities in small melt batches, but that with progressive invigoration of the arc, such compositions are more effectively blended with mantle melts in source regions. Thus, peraluminous magmas provide important details of the nascent Sierran arc and pre-batholithic crustal structure.
Geochemistry & Geophysics↗
Preparation of low strategic metal content superalloys
The properties of modified NIMONIC 115 and UDIMET 720 with reduced levels of cobalt were evaluated. Vacuum induction melted and vacuum arc remelted ingots were hot rolled to 3/4 inch diameter bar. Hot workability was evaluated in terms of the ingot rolling behavior and the hot ductility of the as-rolled bar. Variations in workability and bar ductility were correlated to variations in incipient melting temperature and gamma prime solvus, both of which varied with cobalt content. Heat treatments were defined to yield, as far as possible, similar structures from alloy to alloy. At the lowest cobalt levels N-115 workability was severely limited and the alloys could not be worked to bar. It is suggested that incipient melting in combination with heavy grain boundary carbide precipitation reduced ingot workability. Final heat treatment of modified alloys was difficult in the situation where the gamma prime solvus temperature was close to the incipient melting point, indicating that it may not be feasible to fully solution low cobalt alloys to obtain the large grain size required for optimum creep resistance.
Sczerzenie, F. E.↗
Determination of work functions near melting points of refractory metals by using a direct-current arc.
A direct-current arc in argon at atmospheric pressure was used to determine effective work functions of refractory metals, including tantalum, tungsten, molybdenum, and niobium. The procedure is experimentally advantageous, because surface cleanliness of the specimen is not critical, high vacuum is not required, and the anode-cathode spacing is not critical. The experimental procedure involves striking an arc to a metal wire cathode to form a melted ball having an emitting area defined by its diameter. The literature melting point of the metal is taken as the emitting temperature. By using these parameters and the known arc current, effective work functions were calculated from the Richardson-Dushman equation. The calculated work functions agree with recommended handbook values to within about 0.1 V and have typical repeatabilities of 0.02 V.
Gordon, W. A.↗
Computational Methods for Multi-Physics Simulation of Melting in Steelmaking
Iron and steel production accounts for approximately 8% of global carbon dioxide (CO) emissions. Pathways to decarbonize include replacing fossil fuels in iron ore reduction and electrifying other steelmaking processes. Iron pellets produced by hydrogen, called Hydrogen Direct Reduced Iron (HDRI), have property differences from those produced using conventional DRI processes. These differences may impact melting in electric arc furnaces (EAF) and other downstream processes. The physical properties of iron pellets vary significantly with temperature during heating, complicating predictions of their behavior. In this project, we seek to develop an integrated simulation, including the fluid flow and convective thermal transport around the pellet particle. We also examine conduction and phase changes within the particle as they impact the melting process. We use adaptive mesh refinement (AMR) to resolve both the changing size of the particle and the complex physics of the interaction between the pellet and the surrounding fluid. We base our simulations on the AMReX-incflo module, which allows large-scale Navier-Stokes simulation while resolving the changing particle size during melting. As we advance our numerical tools, we anticipate an improved understanding of the dynamics of HDRI melting, which will, in turn, accelerate the adoption of low-carbon technologies in the steelmaking industry.
AMReX↗
Editors’ Choice—Molten Salt Electrolysis in Chloride Melts for Energy-Efficient Iron Metal Production
This study explores chloride molten salt electrolysis (CMSE) as a promising route for energy-efficient iron metal (Fe) production. Moderate temperature (500 °C) LiCl-KCl molten salts offer excellent thermodynamic stability, high ionic conductivity and diffusivity, and high solubility for FeCl 3 , thereby enabling efficient Fe metal extraction at high electrowinning rates. Here, we demonstrate the two essential steps for converting taconite ore into Fe metal. First, Fe 2 O 3 from taconite pellets was selectively leached in HCl yielding a high-purity FeCl 3 aqueous solution, while the gangue components settled at the bottom. Then, anhydrous FeCl 3 was electrolyzed in a LiCl-KCl eutectic molten salt at 500 °C at high current density (1 A cm −2 ) and at high Coulombic efficiency (>85%). Analysis of the electrowon Fe deposits revealed dendritic structures with purity of >99 wt%, which could be further improved to nearly 100 wt% through arc re-melting. CMSE offers low specific energy consumption (3.7 kWhr kg −1 ), competitive with H 2 -DRI and other electrolytic approaches being pursued globally. Our findings underscore the potential of CMSE as an energy-efficient route for electrosynthesis of Fe metal.
36 MATERIALS SCIENCE↗
Surface Fatigue Tests Of M50NiL Gears And Bars
Report presents results of tests of steels for use in gears and bearings of advanced aircraft. Spur-gear endurance tests and rolling-element surface fatigue tests performed on gear and bar specimens of M50NiL steel processed by vacuum induction melting and vacuum arc remelting (VIM-VAR). Compares results of tests with similar tests of specimens of VIM-VAR AISI 9310 steel and of AISI 9310 steel subjected to VAR only.
Townsend, Dennis P.↗
Comparative Study of Additively Manufactured Inconel 625 In the As-Built and Heat-Treated Condition
This study was conducted to characterize the microstructure and mechanical properties of Inconel 625 manufactured with laser powder bed fusion (L-PBF), electron beam melting (EBM), wire arc additive manufacturing (WAAM), electron beam directed energy deposition (EB-DED), laser powder directed energy deposition (LP-DED), and laser wire directed energy deposition (LW-DED) in both the as built and heat-treated condition. The heat treatment in this study included stress relieving, hot isostatic pressure (HIP), and solution treatment. The effects of the heat treatment on the grain widths and hardness of the alloy will be observed across the technologies before and after heat-treatment. At the end of this study there will be a comparative analysis of the alloy Inconel 625 across the six technologies.
V Luna↗
Toolpath considerations for DED: Arc and laser welding
Directed energy deposition (DED) is a form of additive manufacturing that uses localized melted metal, similar to traditional arc welding, to construct an object. In comparison to polymer systems, metal systems can exert additional control over the build process through manipulation of the pool of melted metal, called the “melt pool.” This is especially important to maintain appropriate layer heights and create high quality builds. Additionally, metal systems allow site-specific control of the printed part, which enables advanced construction techniques that would otherwise not be possible. However, both of these types of control require support from the slicing software and, potentially, sensor feedback. This chapter will discuss these control processes and their basic implementation in a slicing program. The processes described here lay the foundation for more advanced solutions, particularly sensor feedback, that will be discussed later.
Borish, Michael↗
Rolling-element fatigue life of AMS 5749 corrosion resistant, high temperature bearing steel
The rolling element fatigue lives of AMS 5749 and AISI M-50 were compared in tests run in the five ball fatigue tester and the rolling contact fatigue tester. The effects of double vacuum melting and retained austenite on the life of AMS 5749 were determined in five ball fatigue tests. The double vacuum melting process consisted of induction vacuum melting followed by vacuum arc remelting (VIM-VAR). In the five ball tests, VIM-VAR AMS 5749 gave lives at least six times that of VIM-VAR AISI M-50. Similar tests in the rolling contact fatigue tester showed no significant difference in the lives of the two materials. The rolling element fatigue life of VIM-VAR AMS 5749 was at least 14 times that of vacuum induction melted AMS 5749. A trend toward increased rolling element fatigue life with decreased retained austenite is apparent, but the confidence that all experimental differences are significant is not great.
Parker, R. J.↗