Russian scientists research steel-vanadium-steel laminate for next-gen nuclear reactors
March 24, 2019
Source:
Materials scientists from the Russian National University of Science and Technology (NUST MISIS) announce that they have developed a unique steel-vanadium-steel sandwich material that is able to withstand temperatures of up to 700°C, hard radiation exposure, mechanical stress, and chemical exposure for a long period of time. The material was designed to be used in the shells of nuclear reactor cores.
“The ferritic steel provides corrosion resistance, and the vanadium alloy (V-4Ti-4Cr) provides heat resistance and radiation resistance sufficient to withstand the effects of the ultra-rigid environments of a nuclear reactor," says Aleksandra Baranova, research co-author, post-graduate student of NUST MISIS Department of Metallurgical Science and Physics of Strength.
The maximum operating temperatures of the fuel element shells in the new generation reactors reach 550 to 700°C. Sodium, the liquid metal coolant, acts outside. The loads created are much higher than those that the core shells of existing reactors can withstand.
To close the nuclear fuel cycle in a new generation fast neutron reactor, new structural materials that can provide a higher fuel burn-out are needed. These materials should withstand damaging radiation doses of up to 180-200 dpa (displacements per atom), instead of the maximum 100-130 dpa, that are typical for existing materials.
The researchers say that fabrication problems were solved by the use of complex deformation processes and heat treatment of three-layer billets. The process includes hot co-extrusion (pressing), radial forging, and joint rolling. As a result, a "transition zone" is formed at the boundary of the components, and the alloys diffuse into one another, which provides a high-strength bond.
The research team has reportedly managed to create a prototype of the core shell, which is a monolithic three-layer tube. Laboratory tests are said to show high mechanical strength of the composite at operating temperatures of up to 700°C. In the near future, the team plans to begin long-term studies for radiation resistance.
http://en.misis.ru/
Materials scientists from the Russian National University of Science and Technology (NUST MISIS) announce that they have developed a unique steel-vanadium-steel sandwich material that is able to withstand temperatures of up to 700°C, hard radiation exposure, mechanical stress, and chemical exposure for a long period of time.
Continue reading
GE Aviation’s Catalyst turboprop engine wins award for 3D-printed design
Source:
GE Aviation, Auburn, Alabama, announces that it has been recognized by Aviation Week with a Laureate Award in the Business Aviation category for the GE Catalyst program’s innovative work with additive manufacturing design and implementation.
GE’s Catalyst is the first clean-sheet turboprop engine for the Business and General Aviation market in more than 30 years. It includes more printed components than any production engine in aviation history. More than 800 conventionally manufactured parts have been reduced to 12 additive parts on the engine.
The GE Catalyst engine was chosen by Textron to power the new Cessna Denali and is currently going through certification testing. GE’s work on its newest turboprop has been a worldwide collaboration. It includes 22 GE Aviation facilities in Europe with teams located in the Czech Republic, Poland, Germany, and Italy, as well as 1800 engineers.
“For more than six decades, Aviation Week editors have annually awarded Laureates to great achievers in aerospace and aviation,†said Aviation Week Network Editorial Director Joe Anselmo. “GE Aviation and this year’s winners exemplify the spirit and innovations that are transforming our industry to meet the challenges of tomorrow.â€
Additive components reduce the Catalyst’s weight by five percent while contributing a one percent improvement in specific fuel consumption. Thanks to additive manufacturing, the Catalyst program has benefited with a reduction of cycle time, as well as fewer first article inspections, less inventory, fewer defect opportunities, and a reduction in tooling costs.
In addition, GE Aviation is said to be planning a $50 million expansion to its Auburn additive manufacturing capabilities. Increased capacity will allow the high-volume production of a new jet engine component, the 3D-printed bracket for the GEnx-2B engine program. GE has already invested more than $100 million in its Auburn operation, which began producing the additively manufactured fuel nozzle tip for the LEAP jet engine in 2015. As of October 2018, some 30,000 of these parts had been produced.
www.geaviation.com
GE Aviation, Auburn, Alabama, announces that it has been recognized by Aviation Week with a Laureate Award in the Business Aviation category for the GE Catalyst program’s innovative work with additive manufacturing design and implementation.
Continue reading
Nikon’s XT H 450 CT inspection system includes micro-focus X-ray source for dense parts
Source: ASM International
Nikon Metrology, England, has developed X-ray/CT (computed tomography) systems that inspect the complex inner structures of products and detect any defects within them, all without disassembling the product.
Continue reading
DOE awards $36 million to develop materials for high-temperature heat exchangers
Source:
The U.S. Department of Energy, Washington, announces $36 million in awards for 18 projects as part of the High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP). These project teams seek to develop new approaches and technologies for the design and manufacture of high temperature, high pressure, and highly compact heat exchangers and components.
Durable and affordable higher-temperature heat exchangers could make energy conversion much more efficient, which in turn could reduce fuel consumption, system footprint, capital and operational cost, and emissions. HITEMMP projects will target heat exchangers capable of operating for tens of thousands of hours in temperatures and pressures exceeding 1470°F 800°C and 80 bar (1,160 psi) respectively.
Some examples:
General Electric Company, GE Global Research – Niskayuna, New York
Ultra Performance Heat Exchanger Enabled by Additive Technology (UPHEAT) – $2,500,000.
The GE team will develop a metallic-based, ultra-performance heat exchanger enabled by additive manufacturing technology and capable of operation at 900°C (1652°F) and 250 bar (3626 psi).
The Boeing Company – Huntington Beach, California
Highly Compact Metallic Heat Exchangers for Extreme Environments – $2,397,756.52.
Boeing will develop a compact, extreme environment heat exchanger (EEHX) for application in supercritical carbon dioxide power cycles for hypersonic aircraft and distributed power generation.
United Technologies Research Center (UTRC) – East Hartford, Connecticut
Additive, Topology-Optimized Ultra-Compact Heat Exchanger – $2,100,000
UTRC will develop an ultra-compact, topology-optimized 800°C (1472°F), 250 bar (3626 psi) heat exchanger substantially smaller and substantially more durable than current commercial cross-flow heat exchangers.
CompRex, LLC – De Pere, Wisconsin
Compact Heat Exchanger for High Temperature High Pressure Applications Using Advanced Cermet - – $1,455,000.00
CompRex, LLC aims to realize a transformational and disruptive advancement in heat exchange technology for high temperature (>800°C or 1472°F) and high pressure (80 bar or 1160 psi) applications through use of advanced metal and ceramic composite material, development of a new simplified manufacturing approach, and optimization of heat exchanger design.
For a complete list of projects, visit
https://arpa-e.energy.gov/?q=document/hitemmp-project-descriptions
The U.S. Department of Energy, Washington, announces $36 million in awards for 18 projects as part of the High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP).
Continue reading
Paulo combines HIP and heat treating for AM and cast products with Quintus HIP system
March 20, 2019
Source:
Quintas Technologies, Sweden, announces that Paulo Heat Treating, St. Louis, Mo., has acquired a Quintas hot isostatic press for its Cleveland Division. The press, model QIH 122 M URC, is equipped with Quintus’ proprietary uniform rapid cooling (URC), a feature that improves material properties for products of additive manufacturing and investment casting.
"We see the market for HIP expanding, with a large part attributed to additive manufacturing," says Scott Herzing, Paulo Vice President of Engineering. "We have the leading material knowledge and process expertise to help our customers in this area. The ability to combine HIP and heat treatment will allow us to offer one-stop-shop thermal processing solutions, with faster turnaround times."
The HIP will be installed in Paulo's recently expanded Cleveland Division, in Willoughby, Ohio, which provides specialized brazing and precise vacuum heat treatment. The plant's AS9100 quality management system and Nadcap accreditation make it especially well-suited to serve the needs of the aerospace and power generation industries.
Configured as a Quintus Modularized Solution, a space- and energy-saving profile that simplifies building and civil work and reduces infrastructure investment, the press features a work zone of 26.0 inches (660 mm) in diameter and 68.9 inches (1750 mm) in height. It operates at a maximum temperature of 2,552°F (1,400°C) and maximum pressure of 30,000 psi (2,070 bar).
https://www.quintustechnologies.com
https://www.paulo.com
Quintas Technologies, Sweden, announces that Paulo Heat Treating, St. Louis, Mo., has acquired a Quintas hot isostatic press for its Cleveland Division.
Continue reading
Dual-chamber heat treating furnace hardens and tempers tool steels for transportation
Source:
L&L Special Furnace Co., Aston, Pa., announces that it has shipped a dual-chamber heat treating furnace that will harden tool steels in its upper chamber while its bottom chamber is used for tempering, stress relief, and pre-heating. The furnace was purchased by a manufacturer in the southeastern United States who processes various components used in the production of heavy machinery and transportation equipment.
The L&L model QD836 furnace’s hardening chamber has an effective work zone 16 inches wide by 16 inches high by 32 inches deep. The tempering chamber has an effective work zone 14 inches wide by 14 inches high by 32 inches deep. The top chamber has a uniformity of ±20° above 1200°F, and the bottom chamber has a uniformity of ±10°F from 300°F to 1250°F.
The furnace is controlled by Eurotherm temperature controls with overtemperature protection. Solid-state relays drive the electric heating elements and include heavy-duty, long-lasting 11 gauge thermocouples. All of L&L’s furnaces can be configured with various options and can be specifically tailored to meet thermal needs. L&L also offers furnaces equipped with pyrometry packages to meet ASM2750E and soon-to-be-certified MedAccred guidelines.
Options include a variety of control and recorder configurations. A three-day, all-inclusive startup service is available with each system within the continental United States and Canada. International startup and training service is available by factory quote.
www.llfurnace.com
L&L Special Furnace Co., Aston, Pa., announces that it has shipped a dual-chamber heat treating furnace that will harden tool steels in its upper chamber while its bottom chamber is used for tempering, stress relief, and pre-heating.
Continue reading
Wisconsin Oven builds 35-foot, two-zone gas-fired oven for curing composites
Source:
Wisconsin Oven Corp., East Troy, announces the shipment of a two-zone indirect gas-fired heavy duty walk-in oven to a global manufacturer in the composites industry. This project passed the stringent temperature uniformity requirements to meet BAC 5621 Class 1 Furnaces and Instrumentation Type D specifications.
The composite curing oven has a maximum operating temperature of 450°F and overall chamber dimensions of 12 feet wide, 35 feet long, and 9 feet high. It utilizes a horizontal air flow configuration to maximize heating rates and uniformity. Three total guaranteed temperature uniformity tests were performed to ±5°F, each at set points of 150°F, 250°F, 350°F, and 400° F to meet BAC 5621 Class 1 Furnaces and Instrumentation Type D specifications. These were verified through a 50-point profile (with center door raised), and a 25-point profile (with center door closed) performed separately. All three tests were conducted in an empty oven chamber under static operating conditions.
It has sufficient capability to heat 2000 pounds of material from 70°F to 350°F at an average rate of 10°F per minute. It features three total vertical lift, electrically operated doors; the center door (when in the closed/lowered position) separates each zone into individual chambers. When in the raised position, this center door allows the customer to utilize one main large heating chamber.
Each zone’s exhaust blowers include both VFD’s and modulating dampers to allow a lowered exhaust rate during heating, and capability for accelerated cooling of product during the cooling stage. The vacuum system includes two 2 HP rotary vane vacuum pumps, one for each zone, and a Eurotherm controller for controlling the pressure of each vacuum header. This composite curing oven also features access doors within both end vertical lift doors, personnel safety interior pull cords (to automatically open both end doors), and interior lighting.
www.wisoven.com
Wisconsin Oven Corp., East Troy, announces the shipment of a two-zone indirect gas-fired heavy duty walk-in oven to a global manufacturer in the composites industry.
Continue reading
Seco Warwick reports record order portfolio and 10% sales increase over 2017
Source:
The Seco Warwick Group, Meadville, Pa., reports a record order portfolio of over $106 million after three quarters of 2018, with an operating profit for this period of $5.3 million, and net profit of $3.5 million.
The Group's sales in the first three quarters of 2018 increased by 10% compared to the same period of 2017, reaching a record $106 million. The strong market position is built not only by factories and companies on three continents, but also by stable revenues and a record order portfolio for end-to-end solutions in five product categories.
One category of note is atmosphere heat treatment technology and equipment, the product segment that provided robust sales in 2018. The final results reflect great progress for this product segment, which has prompted continuing investment in this technology and expansion into new markets.
Another product segment that recorded excellent sales results was vacuum metallurgy. A significant increase in sales of vacuum induction melting systems (VIM) in 2018 has already become the success story of the segment. At Purdue University, the Group installed and commissioned a VIM type furnace with a unique oil cooling system - a furnace for infiltrating samples with a zirconium alloy. VIM also was delivered, among other vacuum metallurgy project, to an American company serving the aviation industry.
The aerospace industry built a strong order portfolio, 70% of sales, for the Group in 2018, because equipment from the three segments of the Group are devoted to this sector. Particularly noteworthy are furnaces for vacuum heat treatment. In 2018, 65% of the total volume were designed as customized projects.
www.secowarwick.com
The Seco Warwick Group, Meadville, Pa., reports a record order portfolio of over $106 million after three quarters of 2018, with an operating profit for this period of $5.3 million, and net profit of $3.5 million.
Continue reading
One Minute Mentor: Subcritical anneal to convert pearlite to ferrite
March 18, 2019
Source:
When maximum ductility and good machinability are needed and high strength is not required, ductile iron castings generally are given a full ferritizing anneal. The microstructure thus is converted to ferrite, and the excess carbon is deposited on the existing nodules (Fig. 3a). This treatment produces ASTM grade 60-40-18. Amounts of manganese, phosphorus, and alloying elements such as chromium and molybdenum should be as low as possible for superior machinability, because these elements retard the annealing process.
For subcritial anneal, heat and hold at 705 to 720 °C (1300 to 1330 °F), for one hour per inch of section. Furnace cool at 55 °C/h (100 °F/h) to 345 °C (650 °F). Air cool. The Figure shows the influence of subcritical annealing at 705 °C (1300 °F) for various periods of time on the hardness of four ductile irons. When alloys are present, controlled cooling times through the critical temperature range down to 400 °C (750 °F) must be reduced to below 55 °C/h (100 °F/h).
https://dl.asminternational.org/books/book/9/chapter/109877/Heat-Treating-and-Properties-of-Ductile-Iron
When maximum ductility and good machinability are needed and high strength is not required, ductile iron castings generally are given a full ferritizing anneal.
Continue reading
One Minute Mentor: Subcritical anneal to convert pearlite to ferrite in ductile iron
Source:
When maximum ductility and good machinability are needed and high strength is not required, ductile iron castings generally are given a full ferritizing anneal. The microstructure thus is converted to ferrite, and the excess carbon is deposited on the existing nodules (Fig. 3a). This treatment produces ASTM grade 60-40-18. Amounts of manganese, phosphorus, and alloying elements such as chromium and molybdenum should be as low as possible for superior machinability, because these elements retard the annealing process.
For subcritial anneal, heat and hold at 705 to 720 °C (1300 to 1330 °F), for one hour per inch of section. Furnace cool at 55 °C/h (100 °F/h) to 345 °C (650 °F). Air cool. The Figure shows the influence of subcritical annealing at 705 °C (1300 °F) for various periods of time on the hardness of four ductile irons. When alloys are present, controlled cooling times through the critical temperature range down to 400 °C (750 °F) must be reduced to below 55 °C/h (100 °F/h).
https://dl.asminternational.org/books/book/9/chapter/109877/Heat-Treating-and-Properties-of-Ductile-Iron
When maximum ductility and good machinability are needed and high strength is not required, ductile iron castings generally are given a full ferritizing anneal.
Continue reading 