Development of a Metal Ceramic Composite Crucible. Final CRADA Report for CRADA Number Y-1292-0079 PDF Download

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Languages : en
Pages : 29

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This Cooperative Research and Development Agreement (CRADA) has been a three-year collaboration among the Y-12 Plant Development Division, Blasch Precision Ceramics, Inc., and Surface Alloys, Inc. The purpose of the CRADA was to evaluate the production of a totally new crucible that would be noncarbon and that could perform like graphite. The effort required materials fabricated into a workable crucible. The goal was to produce a crucible that could be induction heated and allow melting of reactive metals without appreciable carbon contamination. The US Department of Energy programs involving casting uranium and its alloys have long been concerned with reducing deleterious carbon pickup that results from the use of graphite crucibles. Therefore, the results of this CRADA provide an alternative that can eliminate carbon pickup from the graphite crucible.

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Languages : en
Pages : 120

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This Cooperative Research and Development Agreement (CRADA) was a mutual research and development (R and D) effort among the participants to investigate a range of advanced manufacturing technologies for two silicon nitride (Si3N4) ceramic materials. The general objective was to identify the most cost-effective part manufacturing processes for the ceramic materials of interest. The focus was determining the relationship between material removal rates, surface quality, and the structural characteristics of each ceramic resulting from three innovative processes. These innovated machining processes were studied using silicon nitride advanced materials. The particular (Si3N4) materials of interest were sintered GS-44 from the Norton Company, and reaction-bonded Ceraloy 147-3. The processes studied included the following activities: (1) direct laser machining; (2) rotary ultrasonic machining; and (3) diamond abrasive grinding, including both resinoid and vitreous-bonded grinding wheels. Both friable and non-friable diamond types were included within the abrasive grinding study. The task also conducted a comprehensive survey of European experience in use of ceramic materials, principally aluminum oxide. Originally, the effort of this task was to extend through a prototype manufacturing demonstration of selected engine components. During the execution of this program, however changes were made to the scope of the project, altering the goals. The Program goal became only the development of assessment of their impacts on product strength and surface condition.

Author: C. J. Janke
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Languages : en
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Electron beam (EB) curing is a technology that promises, in certain applications, to deliver lower cost and higher performance polymer matrix composite (PMC) structures compared to conventional thermal curing processes. PMCs enhance performance by making products lighter, stronger, more durable, and less energy demanding. They are essential in weight- and performance-dominated applications. Affordable PMCs can enhance US economic prosperity and national security. US industry expects rapid implementation of electron beam cured composites in aircraft and aerospace applications as satisfactory properties are demonstrated, and implementation in lower performance applications will likely follow thereafter. In fact, at this time and partly because of discoveries made in this project, field demonstrations are underway that may result in the first fielded applications of electron beam cured composites. Serious obstacles preventing the widespread use of electron beam cured PMCs in many applications are their relatively poor interfacial properties and resin toughness. The composite shear strength and resin toughness of electron beam cured carbon fiber reinforced epoxy composites were about 25% and 50% lower, respectively, than those of thermally cured composites of similar formulations. The essential purpose of this project was to improve the mechanical properties of electron beam cured, carbon fiber reinforced epoxy composites, with a specific focus on composite shear properties for high performance aerospace applications. Many partners, sponsors, and subcontractors participated in this project. There were four government sponsors from three federal agencies, with the US Department of Energy (DOE) being the principal sponsor. The project was executed by Oak Ridge National Laboratory (ORNL), NASA and Department of Defense (DOD) participants, eleven private CRADA partners, and two subcontractors. A list of key project contacts is provided in Appendix A. In order to properly manage the large project team and properly address the various technical tasks, the CRADA team was organized into integrated project teams (IPT's) with each team focused on specific research areas. Early in the project, the end user partners developed ''exit criteria'', recorded in Appendix B, against which the project's success was to be judged. The project team made several important discoveries. A number of fiber coatings or treatments were developed that improved fiber-matrix adhesion by 40% or more, according to microdebond testing. The effects of dose-time and temperature-time profiles during the cure were investigated, and it was determined that fiber-matrix adhesion is relatively insensitive to the irradiation procedure, but can be elevated appreciably by thermal postcuring. Electron beam curable resin properties were improved substantially, with 80% increase in electron beam 798 resin toughness, and {approx}25% and 50% improvement, respectively, in ultimate tensile strength and ultimate tensile strain vs. earlier generation electron beam curable resins. Additionally, a new resin electron beam 800E was developed with generally good properties, and a very notable 120% improvement in transverse composite tensile strength vs. earlier generation electron beam cured carbon fiber reinforced epoxies. Chemical kinetics studies showed that reaction pathways can be affected by the irradiation parameters, although no consequential effects on material properties have been noted to date. Preliminary thermal kinetics models were developed to predict degree of cure vs. irradiation and thermal parameters. These models are continually being refined and validated. Despite the aforementioned impressive accomplishments, the project team did not fully realize the project objectives. The best methods for improving adhesion were combined with the improved electron beam 3K resin to make prepreg and uni-directional test laminates from which composite properties could be determined. Nevertheless, only minor improvements in the composite shear strength, and moderate improvements in the transverse tensile strength, were achieved. The project team was not satisfied with the laminate quality achieved, and low quality (specifically, high void fraction) laminates will compromise the composite properties. There were several problems with the prepregging and fabrication, many of them related to the use of new fiber treatments.

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Languages : en
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