ADVANCED ABRASION RESISTANT MATERIALS FOR MINING

The high-density infrared (HDI) transient-liquid coating (TLC) process was successfully developed and demonstrated excellent, enhanced (5 times higher than the current material and process) wear performance for the selected functionally graded material (FGM) coatings under laboratory simulated, in-service conditions. The mating steel component exhibited a wear rate improvement of approximately one and a half (1.5) times. After 8000 cycles of wear testing, the full-scale component testing demonstrated that the coating integrity was still excellent. Little or no spalling was observed to occur

Definition of prominent thermal mechanisms associated with the buoyancy-induced transport of hafnium-carbide within a solidifying uranium-hafnium alloy

Environmental concerns over uranium wastes generated interest in using existing uranium stockpiles as feed materials. One obstacle to recycling is accumulation of carbon that can degrade as-cast mechanical properties. A program was begun to develop a casting procedure capable of reducing the C content in components made from recycled uranium to levels comparable with virgin feed stock. Trace amounts of Hf are added to form low-density Hf C, which floats to the top of the casting, and can be removed at a later time. Developing this procedure requires modeling carbide transport within solidifying uranium, and this necessitates solving a coupled, nonlinear fluid dynamics, heat transfer, and solution thermodynamics problem. The heat transfer facet was addressed first. Steady-state and transient thermal performance of a laboratory-scale casting assembly was characterized to identify those mechanisms that have a prominent influence on modeling uranium melt solidification. The analysis showed that (1) at least first-order accurate definitions for all thermal mechanisms were required to obtain meaningful agreement with experimental data; (2) prominent mechanisms were thermal contact resistances, liquid uranium natural convection, and internal heat generation; and (3) accurately modeling assembly geometry and enclosure radiation heat transfer would also improve agreement. It was recommended that a second-generation thermal model should be constructed which would include each of these elements

Hydroforming Applications at Oak Ridge

Hydroforming technology is a robust forming process that produces components with high precision and complexity. The goal of this paper is to present a brief description of the sheet hydroforming process with respect to the authors' experience and capabilities. Following the authors' discussion of the sheet-metal forming application, the tubular hydroforming process is described in the context of one of our technology development programs with an automotive industrial partner. After that is a summary of the tubular hydroforming advisor (expert system) development activity, which was a significant part of this overall program based on previous experience in developing a design and manufacturing support hydroforming advisor for the Oak Ridge Y-12 Plant's weapons-component manufacturing needs. Therefore, this paper is divided into three sections: (1) Hydroforming of Stainless Steel Parts, (2) Tubular Hydroforming, and (3) Components of a Tubular Hydroforming Advisor

Effect of pulsed magnetic field pre-treatment of AISI 52100 steel on the coefficient of sliding friction and wear in pin-on-disk tests

Disc specimens manufactured from commercial bearing rollers (AISI 52100 steel, 62–63 HRC) in initial state and after pre-treatment by pulsed magnetic field (PMF) with a magnetic field strength of 1–7 MA/m were tested with sunflower oil using pin-on-disk apparatus. According to the obtained results the treatment causes a reduction in the coefficient of friction and wear. To explain the results, nano- and microhardness tests as well as optical and atomic force microscopy were used. Reasons of the effect of PMF on the friction and wear were discussed.Peer reviewe

Thermal Simulation of Quenching Uranium-0. 75% Titanium Alloy in Water

A computer model, The Quench Simulator, has been developed to simulate and predict in detail the behavior of U-0.75 Ti alloy when quenched at high temperature (about 850/sup 0/C) in cold water. The code allows one to determine the time- and space-dependent distributions of temperature, residual stress, distortion, and microstructure that evolve during the quenching process. The nonlinear temperature- and microstructure-dependent properties, as well as the cooling rate-dependent heats of transformation, are incorporated into the model. The complex boiling heat transfer with its various regimes and other thermal boundary conditions are simulated. Experiments have been performed and incorporated into the model. Both sudden submersion and gradual controlled immersion can be applied. A parametric and sensitivity study has been performed demonstrating the importance of the thermal boundary conditions applied for achieving certain product characteristics. The thermal aspects of the model and its applications are discussed and demonstrated

Effect of 30 T magnetic field on transformations in a novel bainitic steel

The continuous cooling transformation characteristics of novel bainitic steels have been studied, both under ordinary conditionsand whilst subjected to a 30 T magnetic field. The magnetic field has been found to completely change the microstructure obtained,from a mixture of bainite and martensite to one containing an incredibly fine pearlite with an interlamellar spacing of about 50 nm.As a consequence, the pearlite is found to be much harder than any other examples found in the published literature

Simulation for Analysis and Control of Superplastic Forming. Final Report

A joint study was conducted by Oak Ridge National Laboratory (ORNL) and the Pacific Northwest Laboratory (PNL) for the U.S. Department of Energy-Lightweight Materials (DOE-LWM) Program. the purpose of the study was to assess and benchmark the current modeling capabilities with respect to accuracy of predictions and simulation time. Two modeling capabilities with respect to accuracy of predictions and simulation time. Two simulation platforms were considered in this study, which included the LS-DYNA3D code installed on ORNL`s high- performance computers and the finite element code MARC used at PNL. both ORNL and PNL performed superplastic forming (SPF) analysis on a standard butter-tray geometry, which was defined by PNL, to better understand the capabilities of the respective models. The specific geometry was selected and formed at PNL, and the experimental results, such as forming time and thickness at specific locations, were provided for comparisons with numerical predictions. Furthermore, comparisons between the ORNL simulation results, using elasto-plastic analysis, and PNL`s results, using rigid-plastic flow analysis, were performed