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Results for “Casting Operations”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Cylinder block casting slab core cast geometry for sawcut entrance enhancement

An automobile vehicle engine includes multiple water jackets individually formed in a cast engine block proximate to successive ones of multiple cylinder bores. Multiple cast-in place transition regions are individually formed during a casting operation of the cast engine block at entrances to individual ones of the multiple water jackets. Individual ones of multiple sawcuts open into individual ones of the multiple cast-in place transition regions.

Petrus, Ronald John↗
NASA NTRS1985

Method of reducing the green density of a slip cast article

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.

Mangels, John A.↗
DOE OSTI2022

Nuclear data covariances are critical input to determine upper sub-critical limits and to design experiments to increase it [Slides]

This presentation discusses how Upper Subcritical Limits (USL) are key parameters to determine operational limits in nuclear criticality safety evaluations. It also discusses an example of plutonium casting operation using tantalum at LANL PF-4. The Whisper tool at Los Alamos relies on many inputs, including covariance data, leading the presentation to ask if an existing benchmark data be used in Whisper to adjust nuclear data and covariances to justify a higher USL. If not, Whisper can be used to help design an optimal new benchmark experiment. The presentation also seeks to determine what the possible impacts are on USL and operational limits for plutonium casting. In conclusion, nuclear data covariances are used for by Whisper for: GSSL adjustment of nuclear data and covariances, identification of most similar existing benchmark experiments to application, simulation of Upper Subcritical Limit of application, and input to optimization techniques for designing most appropriate new benchmark experiment(s) to meet requirements. This requires a complete set of nuclear data covariances, benchmarks and k-effective sensitivity profiles (for both benchmarks and applications). The presentation concludes by asking if end users should trust results that depend on current covariance data.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Nuclear Data Sensitivity/Uncertainty Studies of Tantalum-Reflected Systems

Tantalum (Ta) is a refractory metal with high melting point and high corrosion resistance. This makes it useful as a mold material for plutonium casting operations. Unfortunately, there are few criticality benchmarks with high nuclear data sensitivities. Given that, it is desirable to design new experiments to provide additional validation data for nuclear criticality safety, which is the objective of the Thales project. Multiple application models were used to represent process conditions (either normal conditions or credible upset conditions) both at Los Alamos National Laboratory (LANL) and Savannah River Site (SRS). A total of 40 application models were obtained. Given this, it was useful to down-select the number of needed application models. This work documents the down-selection based on several nuclear data sensitivity/uncertainty metrics. In addition to showing the result of the specific down-selection used for the Thales project, this work discusses potential ways to represent a large number of application models with a smaller number of proposed experiment designs.

42 ENGINEERING↗
NASA NTRS1992

Development of a CFD code for casting simulation

The task of developing a computational fluid dynamics (CFD) code to accurately model the mold filling phase of a casting operation was accomplished in a systematic manner. First the state-of-the-art was determined through a literature search, a code search, and participation with casting industry personnel involved in consortium startups. From this material and inputs from industry personnel, an evaluation of the currently available codes was made. It was determined that a few of the codes already contained sophisticated CFD algorithms and further validation of one of these codes could preclude the development of a new CFD code for this purpose. With industry concurrence, ProCAST was chosen for further evaluation. Two benchmark cases were used to evaluate the code's performance using a Silicon Graphics Personal Iris system. The results of these limited evaluations (because of machine and time constraints) are presented along with discussions of possible improvements and recommendations for further evaluation.

Murph, Jesse E.↗
DOE OSTI2024

Chlorination of HALEU regulus casting dross

A scoping study was performed for chlorinating dross formed during uranium casting operations. Here, the purpose is to minimize the losses of uranium to dross wastes. The dross is primarily a mixture of uranium metal and uranium oxide with a minor fraction of crucible and crucible coating materials. The reaction chemistries were performed in a carrier salt of LiCl-KCl eutectic at 500 °C. The addition of FeCl 2 chlorinated the uranium metal to UCl 3 , by reducing the FeCl 2 to iron metal. After the uranium metal was chlorinated, zirconium metal was added to the salt. The residual FeCl 2 chlorinated the zirconium metal to ZrCl 4 , by reducing the FeCl 2 to iron metal. In turn, the ZrCl 4 chlorinated the uranium oxide to UCl 3 , by converting the ZrCl 4 to zirconium oxide. The effectiveness of the chlorination reactions was qualitatively verified by cyclic voltammograms that indicated the presence or absence of FeCl 2 and UCl 3 in the salt.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1969

Machining of low percentage beryllium copper alloys

Airborne beryllium sampling during machining of low percentage beryllium-copper alloys shows that normal dry machining creates 45.2 microgram/cu m of airborne beryllium in the casting operators breathing zone and 2.3 microgram/cu m in an adjacent machine working area. A small vacuum system placed over the tool effectively removes airborne beryllium in the breathing zone sample to 0.2 microgram/cu m.

Habermeyer, J. G.↗
NASA NTRS1973

Semiconductor surface protection material

A method and a product for protecting semiconductor surfaces is disclosed. The protective coating material is prepared by heating a suitable protective resin with an organic solvent which is solid at room temperature and converting the resulting solution into sheets by a conventional casting operation. Pieces of such sheets of suitable shape and thickness are placed on the semiconductor areas to be coated and heat and vacuum are then applied to melt the sheet and to drive off the solvent and cure the resin. A uniform adherent coating, free of bubbles and other defects, is thus obtained exactly where it is desired.

Packard, R. D.↗
NASA NTRS1996

Demonstration of a Real Time Capability to Produce Tidal Heights and Currents for Naval Operational Use: A Cast Study for the West Coast of Africa (Liberia)

This report documents an existing capability to produce operationally relevant products on sea level and currents from a tides/storm surge model for any coastal region around the world within 48 hours from the time of the request. The model is ready for transition to the Naval Oceanographic Office (NAVOCEANO) for potential contingency use anywhere around the world. A recent application to naval operations offshore Liberia illustrates this. Mississippi State University, in collaboration with the University of Colorado and NAVOCEANO, successfully deployed the Colorado University Rapidly Relocatable Nestable Tides and Storm Surge (CURReNTSS) model that predicts sea surface height, tidal currents and storm surge, and provided operational products on tidal sea level and currents in the littoral region off south-western coast of Africa. This report summarizes the results of this collaborative effort in an actual contingency use of the relocatable model, summarizes the lessons learned, and provides recommendations for further evaluation and transition of this modeling capability to operational use.

CASE STUDIES↗
NASA NTRS1970

Salvaging surface-damaged aluminum castings

Repair operation for damaged aluminum parts includes anodizing the part, removing the oxide layer, filling the pit or scratch with copper, capping the fill with cadmium, and hand polishing.

Hanna, T. L.↗
DOE OSTI2025

On nonlocal problems with Neumann boundary conditions: scaling and convergence for nonlocal operators and solutions

Formulations of Neumann-type boundary conditions for boundary value problems in the nonlocal framework are beset with difficulties, some related to the choice of a proper scaling. Here we identify a space-dependent scaling for a nonlocal Neumann operator, for which we prove linear in δ (δ being the radius for the support for the kernel) convergence of the Neumann operator and $\mathcal{O}$(δ 2 ) convergence of solutions to their classical counterparts. The pointwise-like convergence of the nonlocal normal operator is cast as a new type of two-scale operator-point convergence, which we call condensated convergence . The results hold for general integrable kernels, a setting which is favored in numerical simulations. We support this analysis with numerical convergence studies using a piecewise linear discontinuous Galerkin discretization and show an $\mathcal{O}$(δ 2 ) rate of convergence of solutions, also exhibiting an $\mathcal{O}$(h 2 ) convergence, where h is the mesh size.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1972

Space rescue operations in the early 1980's.

Discussion of planning requirements for space rescue missions in connection with an emergency situation involving a manned satellite with a small crew. A space rescue mission may be divided basically into three major operational phases including the response time phase, the phase concerned with the rescue operations, and the final phase which begins with the casting-off operation from the rendezvous position with the distressed vehicle. The types of possible emergency situations are discussed together with the space rescue equipment, a pressurized emergency module, an unpressurized emergency module, a portable airlock, an attachable docking fixture, a fluid jet type detumble system, a stick-on rocket type detumble system, and an antitumbling space vehicle.

Wild, J. W.↗
NASA NTRS2019

ISEP: A Joint SRAG/CCMC Collaboration to Improve Mitigation of Space Weather Effects on Crew Health in the Exo-LEO Era

The Space Radiation Analysis Group (SRAG) at Johnson Space Center (JSC) is tasked with monitoring changes to space weather and mitigating any resultant impacts to crew health and safety. As human spaceflight goals extend from Low-Earth Orbit (LEO) missions like the International Space Station (ISS) to the moon, Mars and beyond, SRAG will need to update their current approach for crew monitoring of and protection from radiation exposure due to energetic Solar Particle Events (ESPEs). Challenges faced in planning exo-LEO missions include the lack of protection from the Earth’s geomagnetic field employed by the ISS in addition to limited communication capability between the crew and the ground. In the event of an ESPE, the current ISS trajectory ensures that the vehicle is only traveling through fields of higher radiation exposure for a brief period of time; the Earth’s geomagnetic field prevents the penetration of the high-energy particles of concern throughout the majority of the orbit. Exo-LEO missions, on the other hand, require that the vehicle travel through free space, exposing vehicle and crew to the full impact of the ESPE. NASA has combined multiple approaches to resolve this radiation exposure issue. New vehicles are designed to take advantage of advances in particle transport modeling capabilities and shielding technology, allowing redistribution of mass throughout the vehicle to areas of thinner shielding when the energetic particle flux has increased to levels of concern. Although vehicle shielding is an important aspect of radiation exposure protection, there is a continued requirement to monitor and predict the space weather environment. To this end, SRAG maintains a console position in Mission Control with 24/7 mission support capability. In the event of increased solar activity, SRAG collaborates with the Flight Control Team (FCT) to determine if crew action (i.e., shelter) is required. During any increase in solar activity, the FCT needs three pieces of information to effectively decide the crew response in light of other required mission tasks: if an event (ESPE) will occur, how ‘intense’ an observed event will be, and how long will an observed event will last. An ideal alert system limits false alarms, therefore causing the crew to take action unnecessarily, without ignoring events that pose a hazard to the crew. SRAG’s current operational concept for ISS missions focuses on short-term forecasts, best described as ‘now-casting’. Console operators are in daily communication with the Space Weather Prediction Center (SWPC) for situational awareness purposes. When conditions exist that may lead to increased solar activity, operators receive notifications from SWPC. In the case of a well-connected ESPE, the console operator may only have on the order of minutes to several hours to notify the FCT of the event and provide a recommendation for crew action. As NASA shifts to exo-LEO missions, the increased time in free space as well as the reduced ability to communicate with the crew will force a transition in crew protection strategy that emphasizes improvments to both the accuracy and the lead time in forecasting capabilities.

Barzilla, Janet E.↗