Horizontal electromagnetic casting of thin metal sheets

DOEpatents

Hull, John R.; Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

1987-01-01

Thin metal sheets are cast by magnetically suspending molten metal deposited within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled to form a solid metal sheet. Magnetic flux increases as the molten metal sheet moves downward and decreases as the molten metal sheet moves upward to stabilize the sheet and maintain it in equilibrium as it is linearly displaced and solidified by cooling gases. A conducting shield is electrically coupled to the molten metal sheet by means of either metal sheet engaging rollers or brushes on the solidified metal, and by means of an electrode in the vessel containing the molten metal thereby providing a return path for the eddy currents induced in the metal sheet by the AC coil generated magnetic flux. Variation in the geometry of the conducting shield allows the magnetic flux between the metal sheet and the conducting shield to be varied and the thickness in surface quality of the metal sheet to be controlled. Side guards provide lateral containment for the molten metal sheet and stabilize and shape the magnetic field while a leader sheet having electromagnetic characteristics similar to those of the metal sheet is used to start the casting process and precedes the molten metal sheet through the magnet and forms a continuous sheet therewith. The magnet may be either U-shaped with a single racetrack coil or may be rectangular with a pair of facing bedstead coils.

Horizontal electromagnetic casting of thin metal sheets

DOEpatents

Hull, John R.; Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

1988-01-01

Thin metal sheets are cast by magnetically suspending molten metal deposited within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled to form a solid metal sheet. Magnetic flux increases as the molten metal sheet moves downward and decreases as the molten metal sheet moves upward to stabilize the sheet and maintain it in equilibrium as it is linearly displaced and solidified by cooling gases. A conducting shield is electrically coupled to the molten metal sheet by means of either metal sheet engaging rollers or brushes on the solidified metal, and by means of an electrode in the vessel containing the molten metal thereby providing a return path for the eddy currents induced in the metal sheet by the AC coil generated magnetic flux. Variation in the geometry of the conducting shield allows the magnetic flux between the metal sheet and the conducting shield to be varied and the thickness in surface quality of the metal sheet to be controlled. Side guards provide lateral containment for the molten metal sheet and stabilize and shape the magnetic field while a leader sheet having electromagnetic characteristics similar to those of the metal sheet is used to start the casting process and precedes the molten metal sheet through the magnet and forms a continuous sheet therewith. The magnet may be either U-shaped with a single racetrack coil or may be rectangular with a pair of facing bedstead coils.

Novel waste printed circuit board recycling process with molten salt.

PubMed

Riedewald, Frank; Sousa-Gallagher, Maria

2015-01-01

The objective of the method was to prove the concept of a novel waste PCBs recycling process which uses inert, stable molten salts as the direct heat transfer fluid and, simultaneously, uses this molten salt to separate the metal products in either liquid (solder, zinc, tin, lead, etc.) or solid (copper, gold, steel, palladium, etc.) form at the operating temperatures of 450-470 °C. The PCB recovery reactor is essentially a U-shaped reactor with the molten salt providing a continuous fluid, allowing molten salt access from different depths for metal recovery. A laboratory scale batch reactor was constructed using 316L as suitable construction material. For safety reasons, the inert, stable LiCl-KCl molten salts were used as direct heat transfer fluid. Recovered materials were washed with hot water to remove residual salt before metal recovery assessment. The impact of this work was to show metal separation using molten salts in one single unit, by using this novel reactor methodology. •The reactor is a U-shaped reactor filled with a continuous liquid with a sloped bottom representing a novel reactor concept.•This method uses large PCB pieces instead of shredded PCBs as the reactor volume is 2.2 L.•The treated PCBs can be removed via leg B while the process is on-going.

Novel waste printed circuit board recycling process with molten salt

PubMed Central

Riedewald, Frank; Sousa-Gallagher, Maria

2015-01-01

The objective of the method was to prove the concept of a novel waste PCBs recycling process which uses inert, stable molten salts as the direct heat transfer fluid and, simultaneously, uses this molten salt to separate the metal products in either liquid (solder, zinc, tin, lead, etc.) or solid (copper, gold, steel, palladium, etc.) form at the operating temperatures of 450–470 °C. The PCB recovery reactor is essentially a U-shaped reactor with the molten salt providing a continuous fluid, allowing molten salt access from different depths for metal recovery. A laboratory scale batch reactor was constructed using 316L as suitable construction material. For safety reasons, the inert, stable LiCl–KCl molten salts were used as direct heat transfer fluid. Recovered materials were washed with hot water to remove residual salt before metal recovery assessment. The impact of this work was to show metal separation using molten salts in one single unit, by using this novel reactor methodology. • The reactor is a U-shaped reactor filled with a continuous liquid with a sloped bottom representing a novel reactor concept. • This method uses large PCB pieces instead of shredded PCBs as the reactor volume is 2.2 L. • The treated PCBs can be removed via leg B while the process is on-going. PMID:26150977

Electrolysis of a molten semiconductor

DOE PAGES

Yin, Huayi; Chung, Brice; Sadoway, Donald R.

2016-08-24

Metals cannot be extracted by electrolysis of transition-metal sulfides because as liquids they are semiconductors, which exhibit high levels of electronic conduction and metal dissolution. Herein by introduction of a distinct secondary electrolyte, we reveal a high-throughput electro-desulfurization process that directly converts semiconducting molten stibnite (Sb 2S 3) into pure (99.9%) liquid antimony and sulfur vapour. At the bottom of the cell liquid antimony pools beneath cathodically polarized molten stibnite. At the top of the cell sulfur issues from a carbon anode immersed in an immiscible secondary molten salt electrolyte disposed above molten stibnite, thereby blocking electronic shorting across themore » cell. In conclusion, as opposed to conventional extraction practices, direct sulfide electrolysis completely avoids generation of problematic fugitive emissions (CO 2, CO and SO 2), significantly reduces energy consumption, increases productivity in a single-step process (lower capital and operating costs) and is broadly applicable to a host of electronically conductive transition-metal chalcogenides.« less

Use of Thermodynamic Modeling for Selection of Electrolyte for Electrorefining of Magnesium from Aluminum Alloy Melts

NASA Astrophysics Data System (ADS)

Gesing, Adam J.; Das, Subodh K.

2017-02-01

With United States Department of Energy Advanced Research Project Agency funding, experimental proof-of-concept was demonstrated for RE-12TM electrorefining process of extraction of desired amount of Mg from recycled scrap secondary Al molten alloys. The key enabling technology for this process was the selection of the suitable electrolyte composition and operating temperature. The selection was made using the FactSage thermodynamic modeling software and the light metal, molten salt, and oxide thermodynamic databases. Modeling allowed prediction of the chemical equilibria, impurity contents in both anode and cathode products, and in the electrolyte. FactSage also provided data on the physical properties of the electrolyte and the molten metal phases including electrical conductivity and density of the molten phases. Further modeling permitted selection of electrode and cell construction materials chemically compatible with the combination of molten metals and the electrolyte.

Coated graphite articles useful in metallurgical processes and method for making same

DOEpatents

Holcombe, Cressie E.; Bird, Eugene L.

1995-01-01

Graphite articles including crucibles and molds used in metallurgical processes involving the melting and the handling of molten metals and alloys that are reactive with carbon when in a molten state and at process temperatures up to about 2000.degree. C. are provided with a multiple-layer coating for inhibiting carbon diffusion from the graphite into the molten metal or alloys. The coating is provided by a first coating increment of a carbide-forming metal on selected surfaces of the graphite, a second coating increment of a carbide forming metal and a refractory metal oxide, and a third coating increment of a refractory metal oxide. The second coating increment provides thermal shock absorbing characteristics to prevent delamination of the coating during temperature cycling. A wash coat of unstabilized zirconia or titanium nitride can be applied onto the third coating increment to facilitate release of melts from the coating.

Casting Apparatus Including A Gas Driven Molten Metal Injector And Method

DOEpatents

Trudel, David R.; Meyer, Thomas N.; Kinosz, Michael J.; Arnaud, Guy; Bigler, Nicolas

2003-06-17

The filtering molten metal injector system includes a holder furnace, a casting mold supported above the holder furnace, and at least one molten metal injector supported from a bottom side of the casting mold. The holder furnace contains a supply of molten metal. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The molten metal injector projects into the holder furnace. The molten metal injector includes a cylinder defining a piston cavity housing a reciprocating piston for pumping the molten metal upward from the holder furnace to the mold cavity. The cylinder and piston are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder or the piston includes a molten metal intake for receiving the molten metal into the piston cavity when the holder furnace contains molten metal. A conduit connects the piston cavity to the mold cavity. A molten metal filter is located in the conduit for filtering the molten metal passing through the conduit during the reciprocating movement of the piston. The molten metal intake may be a valve connected to the cylinder, a gap formed between the piston and an open end of the cylinder, an aperture defined in the sidewall of the cylinder, or a ball check valve incorporated into the piston. A second molten metal filter preferably covers the molten metal intake to the injector.

Applications of Laser-Induced Breakdown Spectroscopy (LIBS) in Molten Metal Processing

NASA Astrophysics Data System (ADS)

Hudson, Shaymus W.; Craparo, Joseph; De Saro, Robert; Apelian, Diran

2017-10-01

In order for metals to meet the demand for critical applications in the automotive, aerospace, and defense industries, tight control over the composition and cleanliness of the metal must be achieved. The use of laser-induced breakdown spectroscopy (LIBS) for applications in metal processing has generated significant interest for its ability to perform quick analyses in situ. The fundamentals of LIBS, current techniques for deployment on molten metal, demonstrated capabilities, and possible avenues for development are reviewed and discussed.

Molten metal injector system and method

DOEpatents

Meyer, Thomas N.; Kinosz, Michael J.; Bigler, Nicolas; Arnaud, Guy

2003-04-01

Disclosed is a molten metal injector system including a holder furnace, a casting mold supported above the holder furnace, and a molten metal injector supported from a bottom side of the mold. The holder furnace contains a supply of molten metal having a metal oxide film surface. The bottom side of the mold faces the holder furnace. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The injector projects into the holder furnace and is in fluid communication with the mold cavity. The injector includes a piston positioned within a piston cavity defined by a cylinder for pumping the molten metal upward from the holder furnace and injecting the molten metal into the mold cavity under pressure. The piston and cylinder are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder further includes a molten metal intake for receiving the molten metal into the piston cavity. The molten metal intake is located below the metal oxide film surface of the molten metal when the holder furnace contains the molten metal. A method of injecting molten metal into a mold cavity of a casting mold is also disclosed.

Investigation of molten pool oscillation during GMAW-P process based on a 3D model

NASA Astrophysics Data System (ADS)

Wang, L. L.; Lu, F. G.; Cui, H. C.; Tang, X. H.

2014-11-01

In order to better reveal the oscillation mechanism of the pulsed gas metal arc welding (GMAW-P) process due to an alternately varied welding current, arc plasma and molten pool oscillation were simulated through a self-consistent three-dimensional model. Based on an experimental analysis of the dynamic variation of the arc plasma and molten pool captured by a high-speed camera, the model was validated by comparison of the measured and predicted results. The calculated results showed that arc pressure was the key factor causing the molten pool to oscillate. The variation in arc size and temperature from peak time to base time resulted in a great difference in the heat input and arc pressure acting on the molten pool. The surface deformation of the molten pool due to the varying degrees of arc pressure induced alternate displacement and backflow in the molten metal. The periodic iteration of deeper and shallower surface deformation, drain and backflow of molten metal caused the molten pool to oscillate at a certain frequency. In this condition, the arc pressure at the peak time is more than six times higher than that at the base time, and the maximum surface depression is 1.4 mm and 0.6 mm, respectively, for peak time and base time.

SEPARATION OF TIN FROM ALLOYS

DOEpatents

Kattner, W.T.

1959-08-11

A process is described for recovering tin from bronze comprising melting the bronze; slowly cooling the melted metal to from 280 to 240 deg C whereby eta- phase bronze crystallizes; separating the eta-bronze crystals from the liquid metal by mechanical means; melting the separated crystals; slowly cooling the melted eta-crystals to a temperature from 520 to 420 deg C whereby crystals of epsilonbronze precipitate; removing said epsilon-crystals from the remaining molten metal; and reintroducing the remaining molten metal into the process for eta-crystallization.

Electromagnetic augmentation for casting of thin metal sheets

DOEpatents

Hull, John R.

1989-01-01

Thin metal sheets are cast by magnetically levitating molten metal deposited in a mold within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled by the water-cooled walls of the mold to form a solid metal sheet. A conducting shield is electrically coupled to the molten metal sheet to provide a return path for eddy currents induced in the metal sheet by the current in the AC conducting coils. In another embodiment, a DC conducting coil is coupled to the metal sheet for providing a direct current therein which interacts with the magnetic field to levitate the moving metal sheet. Levitation of the metal sheet in both molten and solid forms reduces its contact pressure with the mold walls while maintaining sufficient engagement therebetween to permit efficient conductive cooling by the mold through which a coolant fluid may be circulated. The magnetic fields associated with the currents in the aforementioned coils levitate the molten metal sheet while the mold provides for its lateral and vertical confinement. A leader sheet having electromagnetic characteristics similar to those of the molten metal sheet is used to start the casing process and precedes the molten metal sheet through the yoke/coil arrangement and mold and forms a continuous sheet therewith. The yoke/coil arrangement may be either U-shaped with a single racetrack coil or may be rectangular with a pair of spaced, facing bedstead coils.

Influence of processing factors on the physical metallurgy of LENS deposited 316L stainless steel.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yang, Nancy Y. C.; Yee, Joshua Keng; Zheng, Baolong

2015-12-01

Directed energy deposition (DED) is a type of additive manufacturing (AM) process; Laser Engineered Net Shaping (LENS) is a commercial DED process. We are developing LENS technology for printing 316L stainless steel components for structural applications. It is widely known that material properties of AM components are process dependent, attributed to different molten metal incorporation and thermal transport mechanisms. This investigation focuses on process-structure-property relationships for LENS deposits for enabling the process development and optimization to control material property. We observed interactions among powder melting, directional molten metal flow, and the molten metal solidification. The resultant LENS induced microstructure foundmore » to be dictated by the process-related characteristics, i.e., interpass boundaries from multi-layer deposition, molten metal flow lines, and solidification dendrite cells. Each characteristic bears the signature of the unique localized thermal history during deposition. Correlation observed between localized thermal transport, resultant microstructure, and its subsequent impact on the mechanical behavior of the current 316L is discussed. We also discuss how the structures of interpass boundaries are susceptible to localized recrystallization, grain growth and/or defect formation, and therefore, heterogeneous mechanical properties due to the adverse presence of unmelted powder inclusions.« less

Electrolytic production of metals using a resistant anode

DOEpatents

Tarcy, Gary P.; Gavasto, Thomas M.; Ray, Siba P.

1986-01-01

An electrolytic process comprising evolving oxygen on an anode in a molten salt, the anode comprising an alloy comprising a first metal and a second metal, both metals forming oxides, the oxide of the first metal being more resistant than the second metal to attack by the molten salt, the oxide of the second metal being more resistant than the first metal to the diffusion of oxygen. The electrode may also be formed of CuAlO.sub.2 and/or Cu.sub.2 O.

Studies of metals electroprocessing in molten salts

NASA Technical Reports Server (NTRS)

Sadoway, D. R.

1982-01-01

Fluid flow patterns in molten salt electrolytes were observed in order to determine how mass transport affects the morphology of the metal deposit. Studies conducted on the same metal, both in aqueous electrolytes in which coherent solid electrodeposits are produced, as well as in transparent molten salt electrolytes are described. Process variables such as current density and composition of the electrolyte are adjusted to change the morphology of the electrodeposit and, thus, to permit the study of the nature of electrolyte flow in relation to the quality of the electrodeposit.

Process for casting hard-faced, lightweight camshafts and other cylindrical products

DOEpatents

Hansen, Jeffrey S.; Turner, Paul C.; Argetsinger, Edward R.; Wilson, Rick D.

1996-01-01

A process for casting a hard-faced cylindrical product such as an automobile camshaft includes the steps of: (a) preparing a composition formed from a molten base metal and an additive in particle form and having a hardness value greater than the hardness value of the base metal; (b) introducing the composition into a flask containing a meltable pattern of a cylindrical product such as an automobile camshaft to be manufactured and encased in sand to allow the composition to melt the pattern and assume the shape of the pattern within the sand; and (c) rotating the flask containing the pattern about the longitudinal axes of both the flask and the pattern as the molten base metal containing the additive in particle form is introduced into the flask to cause particles of the additive entrained in the molten base metal to migrate by centrifugal action to the radial extremities of the pattern and thereby provide a cylindrical product having a hardness value greater at it's radial extremities than at its center when the molten base metal solidifies.

Apparatus and Method for Increasing the Diameter of Metal Alloy Wires Within a Molten Metal Pool

DOEpatents

Hartman, Alan D.; Argetsinger, Edward R.; Hansen, Jeffrey S.; Paige, Jack I.; King, Paul E.; Turner, Paul C.

2002-01-29

In a dip forming process the core material to be coated is introduced directly into a source block of coating material eliminating the need for a bushing entrance component. The process containment vessel or crucible is heated so that only a portion of the coating material becomes molten, leaving a solid portion of material as the entrance port of, and seal around, the core material. The crucible can contain molten and solid metals and is especially useful when coating core material with reactive metals. The source block of coating material has been machined to include a close tolerance hole of a size and shape to closely fit the core material. The core material moves first through the solid portion of the source block of coating material where the close tolerance hole has been machined, then through a solid/molten interface, and finally through the molten phase where the diameter of the core material is increased. The crucible may or may not require water-cooling depending upon the type of material used in crucible construction. The system may operate under vacuum, partial vacuum, atmospheric pressure, or positive pressure depending upon the type of source material being used.

Apparatus and method for increasing the diameter of metal alloy wires within a molten metal pool

DOEpatents

Hartman, Alan D.; Argetsinger, Edward R.; Hansen, Jeffrey S.; Paige, Jack I.; King, Paul E.; Turner, Paul C.

2002-01-29

In a dip forming process the core material to be coated is introduced directly into a source block of coating material eliminating the need for a bushing entrance component. The process containment vessel or crucible is heated so that only a portion of the coating material becomes molten, leaving a solid portion of material as the entrance port of, and seal around, the core material. The crucible can contain molten and solid metals and is especially useful when coating core material with reactive metals. The source block of coating material has been machined to include a close tolerance hole of a size and shape to closely fit the core material. The core material moves first through the solid portion of the source block of coating material where the close tolerance hole has been machined, then through a solid/molten interface, and finally through the molten phase where the diameter of the core material is increased. The crucible may or may not require water-cooling depending upon the type of material used in crucible construction. The system may operate under vacuum, partial vacuum, atmospheric pressure, or positive pressure depending upon the type of source material being used.

NITRIC ACID PICKLING PROCESS

DOEpatents

Boller, E.R.; Eubank, L.D.

1958-08-19

An improved process is described for the treatment of metallic uranium surfaces preparatory to being given hot dip coatings. The process consists in first pickling the uraniunn surInce with aqueous 50% to 70% nitric acid, at 60 to 70 deg C, for about 5 minutes, rinsing the acid solution from the uranium article, promptly drying and then passing it through a molten alkali-metal halide flux consisting of 42% LiCl, 53% KCla and 5% NaCl into a molten metal bath consisting of 85 parts by weight of zinc and 15 parts by weight of aluminum

Electromagnetic confinement for vertical casting or containing molten metal

DOEpatents

Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

1991-01-01

An apparatus and method adapted to confine a molten metal to a region by means of an alternating electromagnetic field. As adapted for use in the present invention, the alternating electromagnetic field given by B.sub.y =(2.mu..sub.o .rho.gy).sup.1/2 (where B.sub.y is the vertical component of the magnetic field generated by the magnet at the boundary of the region; y is the distance measured downward form the top of the region, .rho. is the metal density, g is the acceleration of gravity and .mu..sub.o is the permeability of free space) induces eddy currents in the molten metal which interact with the magnetic field to retain the molten metal with a vertical boudnary. As applied to an apparatus for the continuous casting of metal sheets or rods, metal in liquid form can be continuously introduced into the region defined by the magnetic field, solidified and conveyed away from the magnetic field in solid form in a continuous process.

Process for electroslag refining of uranium and uranium alloys

DOEpatents

Lewis, P.S. Jr.; Agee, W.A.; Bullock, J.S. IV; Condon, J.B.

1975-07-22

A process is described for electroslag refining of uranium and uranium alloys wherein molten uranium and uranium alloys are melted in a molten layer of a fluoride slag containing up to about 8 weight percent calcium metal. The calcium metal reduces oxides in the uranium and uranium alloys to provide them with an oxygen content of less than 100 parts per million. (auth)

Method to prevent/mitigate steam explosions in casting pits

DOEpatents

Taleyarkhan, Rusi P.

1996-01-01

Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water.

Solid oxide membrane-assisted controllable electrolytic fabrication of metal carbides in molten salt.

PubMed

Zou, Xingli; Zheng, Kai; Lu, Xionggang; Xu, Qian; Zhou, Zhongfu

2016-08-15

Silicon carbide (SiC), titanium carbide (TiC), zirconium carbide (ZrC), and tantalum carbide (TaC) have been electrochemically produced directly from their corresponding stoichiometric metal oxides/carbon (MOx/C) precursors by electrodeoxidation in molten calcium chloride (CaCl2). An assembled yttria stabilized zirconia solid oxide membrane (SOM)-based anode was employed to control the electrodeoxidation process. The SOM-assisted controllable electrochemical process was carried out in molten CaCl2 at 1000 °C with a potential of 3.5 to 4.0 V. The reaction mechanism of the electrochemical production process and the characteristics of these produced metal carbides (MCs) were systematically investigated. X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses clearly identify that SiC, TiC, ZrC, and TaC carbides can be facilely fabricated. SiC carbide can be controlled to form a homogeneous nanowire structure, while the morphologies of TiC, ZrC, and TaC carbides exhibit porous nodular structures with micro/nanoscale particles. The complex chemical/electrochemical reaction processes including the compounding, electrodeoxidation, dissolution-electrodeposition, and in situ carbonization processes in molten CaCl2 are also discussed. The present results preliminarily demonstrate that the molten salt-based SOM-assisted electrodeoxidation process has the potential to be used for the facile and controllable electrodeoxidation of MOx/C precursors to micro/nanostructured MCs, which can potentially be used for various applications.

Electrolytic production of metals using a resistant anode

DOEpatents

Tarcy, G.P.; Gavasto, T.M.; Ray, S.P.

1986-11-04

An electrolytic process is described comprising evolving oxygen on an anode in a molten salt, the anode comprising an alloy comprising a first metal and a second metal, both metals forming oxides, the oxide of the first metal being more resistant than the second metal to attack by the molten salt, the oxide of the second metal being more resistant than the first metal to the diffusion of oxygen. The electrode may also be formed of CuAlO[sub 2] and/or Cu[sub 2]O. 2 figs.

A method of measuring a molten metal liquid pool volume

DOEpatents

Garcia, G.V.; Carlson, N.M., Donaldson, A.D.

1990-12-12

A method of measuring a molten metal liquid pool volume and in particular molten titanium liquid pools, including the steps of (a) generating an ultrasonic wave at the surface of the molten metal liquid pool, (b) shining a light on the surface of a molten metal liquid pool, (c) detecting a change in the frequency of light, (d) detecting an ultrasonic wave echo at the surface of the molten metal liquid pool, and (e) computing the volume of the molten metal liquid. 3 figs.

Optimization of chlorine fluxing process for magnesium removal from molten aluminum

NASA Astrophysics Data System (ADS)

Fu, Qian

High-throughput and low operational cost are the keys to a successful industrial process. Much aluminum is now recycled in the form of used beverage cans and this aluminum is of alloys that contain high levels of magnesium. It is common practice to "demag" the metal by injecting chlorine that preferentially reacts with the magnesium. In the conventional chlorine fluxing processes, low reaction efficiency results in excessive reactive gas emissions. In this study, through an experimental investigation of the reaction kinetics involved in this process, a mathematical model is set up for the purpose of process optimization. A feedback controlled chlorine reduction process strategy is suggested for demagging the molten aluminum to the desired magnesium level without significant gas emissions. This strategy also needs the least modification of the existing process facility. The suggested process time will only be slightly longer than conventional methods and chlorine usage and emissions will be reduced. In order to achieve process optimization through novel designs in any fluxing process, a system is necessary for measuring the bubble distribution in liquid metals. An electro-resistivity probe described in the literature has low accuracy and its capability to measure bubble distribution has not yet been fully demonstrated. A capacitance bubble probe was designed for bubble measurements in molten metals. The probe signal was collected and processed digitally. Higher accuracy was obtained by higher discrimination against corrupted signals. A single-size bubble experiment in Belmont metal was designed to reveal the characteristic response of the capacitance probe. This characteristic response fits well with a theoretical model. It is suggested that using a properly designed deconvolution process, the actual bubble size distribution can be calculated. The capacitance probe was used to study some practical bubble generation devices. Preliminary results on bubble distribution generated by a porous plug in Belmont metal showed bubbles much bigger than those in a water model. Preliminary results in molten aluminum showed that the probe was applicable in this harsh environment. An interesting bubble coalescence phenomenon was also observed in both Belmont metal and molten aluminum.

The electrochemical reduction processes of solid compounds in high temperature molten salts.

PubMed

Xiao, Wei; Wang, Dihua

2014-05-21

Solid electrode processes fall in the central focus of electrochemistry due to their broad-based applications in electrochemical energy storage/conversion devices, sensors and electrochemical preparation. The electrolytic production of metals, alloys, semiconductors and oxides via the electrochemical reduction of solid compounds (especially solid oxides) in high temperature molten salts has been well demonstrated to be an effective and environmentally friendly process for refractory metal extraction, functional materials preparation as well as spent fuel reprocessing. The (electro)chemical reduction of solid compounds under cathodic polarizations generally accompanies a variety of changes at the cathode/melt electrochemical interface which result in diverse electrolytic products with different compositions, morphologies and microstructures. This report summarizes various (electro)chemical reactions taking place at the compound cathode/melt interface during the electrochemical reduction of solid compounds in molten salts, which mainly include: (1) the direct electro-deoxidation of solid oxides; (2) the deposition of the active metal together with the electrochemical reduction of solid oxides; (3) the electro-inclusion of cations from molten salts; (4) the dissolution-electrodeposition process, and (5) the electron hopping process and carbon deposition with the utilization of carbon-based anodes. The implications of the forenamed cathodic reactions on the energy efficiency, chemical compositions and microstructures of the electrolytic products are also discussed. We hope that a comprehensive understanding of the cathodic processes during the electrochemical reduction of solid compounds in molten salts could form a basis for developing a clean, energy efficient and affordable production process for advanced/engineering materials.

Casting Apparatus Including A Gas Driven Molten Metal Injector And Method

DOEpatents

Meyer, Thomas N.

2004-06-01

The casting apparatus (50) includes a holding vessel (10) for containing a supply of molten metal (12) and a casting mold (52) located above the holding vessel (10) and having a casting cavity (54). A molten metal injector (14) extends into the holding vessel (10) and is at least partially immersed in the molten metal (12) in the holding vessel (10). The molten metal injector (14) is in fluid communication with the casting cavity (54). The molten metal injector (14) has an injector body (16) defining an inlet opening (24) for receiving molten metal into the injector body (16). A gas pressurization source (38) is in fluid communication with the injector body (16) for cyclically pressurizing the injector body (16) and inducing molten metal to flow from the injector body (16) to the casting cavity (54). An inlet valve (42) is located in the inlet opening (24) in the injector body (16) for filling molten metal into the injector body (16). The inlet valve (42) is configured to prevent outflow of molten metal from the injector body (16) during pressurization and permit inflow of molten metal into the injector body (16) after pressurization. The inlet valve (42) has an inlet valve actuator (44) located above the surface of the supply of molten metal (12) and is operatively connected to the inlet valve (42) for operating the inlet valve (42) between open and closed positions.

Molten salt extraction process for the recovery of valued transition metals from land-based and deep-sea minerals

DOEpatents

Maroni, V.A.; von Winbush, S.

1987-05-01

A process for extracting transition metals and particularly cobalt and manganese together with iron, copper and nickel from low grade ores (including ocean-floor nodules) by converting the metal oxides or other compositions to chlorides in a molten salt, and subsequently using a combination of selective distillation at temperatures below about 500/degree/C, electrolysis at a voltage not more negative that about /minus/1.5 volt versus Ag/AgCl, and precipitation to separate the desired manganese and cobalt salts from other metals and provide cobalt and manganese in metallic forms or compositions from which these metals may be more easily recovered.

Molten salt extraction process for the recovery of valued transition metals from land-based and deep-sea minerals

DOEpatents

Maroni, Victor A.; von Winbush, Samuel

1988-01-01

A process for extracting transition metals and particularly cobalt and manganese together with iron, copper and nickel from low grade ores (including ocean-floor nodules) by converting the metal oxides or other compositions to chlorides in a molten salt, and subsequently using a combination of selective distillation at temperatures below about 500.degree. C., electrolysis at a voltage not more negative than about -1.5 volt versus Ag/AgCl, and precipitation to separate the desired manganese and cobalt salts from other metals and provide cobalt and manganese in metallic forms or compositions from which these metals may be more easily recovered.

Method and apparatus for atomization and spraying of molten metals

DOEpatents

Hobson, David O.; Alexeff, Igor; Sikka, Vinod K.

1990-01-01

A method and device for dispersing molten metal into fine particulate spray, the method comprises applying an electric current through the molten metal and simultaneously applying a magnetic field to the molten metal in a plane perpendicular to the electric current, whereby the molten metal is caused to form into droplets at an angle perpendicular to both the electric current and the magnetic field. The device comprises a structure for providing a molten metal, appropriately arranged electrodes for applying an electric current through the molten metal, and a magnet for providing a magnetic field in a plane perpendicular to the electric current.

Method and apparatus for atomization and spraying of molten metals

DOEpatents

Hobson, D.O.; Alexeff, I.; Sikka, V.K.

1988-07-19

A method and device for dispersing molten metal into fine particulate spray, the method comprises applying an electric current through the molten metal and simultaneously applying a magnetic field to the molten metal in a plane perpendicular to the electric current, whereby the molten metal is caused to form into droplets at an angle perpendicular to both the electric current and the magnetic field. The device comprises a structure for providing a molten metal, appropriately arranged electrodes for applying an electric current through the molten metal, and a magnet for providing a magnetic field in a plane perpendicular to the electric current. 11 figs.

Method for removing acid gases from a gaseous stream

DOEpatents

Gorin, Everett; Zielke, Clyde W.

1981-01-01

In a process for hydrocracking a heavy aromatic polynuclear carbonaceous feedstock containing reactive alkaline constituents to produce liquid hydrocarbon fuels boiling below about 475.degree. C. at atmospheric pressure by contacting the feedstock with hydrogen in the presence of a molten metal halide catalyst, thereafter separating a gaseous stream containing hydrogen, at least a portion of the hydrocarbon fuels and acid gases from the molten metal halide and regenerating the molten metal halide, thereby producing a purified molten metal halide stream for recycle to the hydrocracking zone, an improvement comprising; contacting the gaseous acid gas, hydrogen and hydrocarbon fuels-containing stream with the feedstock containing reactive alkaline constituents to remove acid gases from the acid gas containing stream. Optionally at least a portion of the hydrocarbon fuels are separated from gaseous stream containing hydrogen, hydrocarbon fuels and acid gases prior to contacting the gaseous stream with the feedstock.

Method to prevent/mitigate steam explosions in casting pits

DOEpatents

Taleyarkhan, R.P.

1996-12-24

Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water. 3 figs.

Presence of Li Clusters in Molten LiCl-Li

PubMed Central

Merwin, Augustus; Phillips, William C.; Williamson, Mark A.; Willit, James L.; Motsegood, Perry N.; Chidambaram, Dev

2016-01-01

Molten mixtures of lithium chloride and metallic lithium are of significant interest in various metal oxide reduction processes. These solutions have been reported to exhibit seemingly anomalous physical characteristics that lack a comprehensive explanation. In the current work, the physical chemistry of molten solutions of lithium chloride and metallic lithium, with and without lithium oxide, was investigated using in situ Raman spectroscopy. The Raman spectra obtained from these solutions were in agreement with the previously reported spectrum of the lithium cluster, Li8. This observation is indicative of a nanofluid type colloidal suspension of Li8 in a molten salt matrix. It is suggested that the formation and suspension of lithium clusters in lithium chloride is the cause of various phenomena exhibited by these solutions that were previously unexplainable. PMID:27145895

Method for the regeneration of spent molten zinc chloride

DOEpatents

Zielke, Clyde W.; Rosenhoover, William A.

1981-01-01

In a process for regenerating spent molten zinc chloride which has been used in the hydrocracking of coal or ash-containing polynuclear aromatic hydrocarbonaceous materials derived therefrom and which contains zinc chloride, zinc oxide, zinc oxide complexes and ash-containing carbonaceous residue, by incinerating the spent molten zinc chloride to vaporize the zinc chloride for subsequent condensation to produce a purified molten zinc chloride: an improvement comprising the use of clay in the incineration zone to suppress the vaporization of metals other than zinc. Optionally water is used in conjunction with the clay to further suppress the vaporization of metals other than zinc.

Separation of uranium from (Th,U)O.sub.2 solid solutions

DOEpatents

Chiotti, Premo; Jha, Mahesh Chandra

1976-09-28

Uranium is separated from mixed oxides of thorium and uranium by a pyrometallurgical process in which the oxides are mixed with a molten chloride salt containing thorium tetrachloride and thorium metal which reduces the uranium oxide to uranium metal which can then be recovered from the molten salt. The process is particularly useful for the recovery of uranium from generally insoluble high-density sol-gel thoria-urania nuclear reactor fuel pellets.

Coated Metal Articles and Method of Making

DOEpatents

Boller, Ernest R.; Eubank, Lowell D.

2004-07-06

The method of protectively coating metallic uranium which comprises dipping the metallic uranium in a molten alloy comprising about 20-75% of copper and about 80-25% of tin, dipping the coated uranium promptly into molten tin, withdrawing it from the molten tin and removing excess molten metal, thereupon dipping it into a molten metal bath comprising aluminum until it is coated with this metal, then promptly withdrawing it from the bath.

METHOD OF SEPARATING FISSION PRODUCTS FROM FUSED BISMUTH-CONTAINING URANIUM

DOEpatents

Wiswall, R.H.

1958-06-24

A process is described for removing metal selectively from liquid metal compositions. The method effects separation of flssion product metals selectively from dilute solution in fused bismuth, which contains uraniunn in solution without removal of more than 1% of the uranium. The process comprises contacting the fused bismuth with a fused salt composition consisting of sodium, potassium and lithium chlorides, adding to fused bismuth and molten salt a quantity of bismuth chloride which is stoichiometrically required to convert the flssion product metals to be removed to their chlorides which are more stable in the fused salt than in the molten metal and are, therefore, preferentially taken up in the fused salt phase.

Method of measuring a liquid pool volume

DOEpatents

Garcia, G.V.; Carlson, N.M.; Donaldson, A.D.

1991-03-19

A method of measuring a molten metal liquid pool volume and in particular molten titanium liquid pools is disclosed, including the steps of (a) generating an ultrasonic wave at the surface of the molten metal liquid pool, (b) shining a light on the surface of a molten metal liquid pool, (c) detecting a change in the frequency of light, (d) detecting an ultrasonic wave echo at the surface of the molten metal liquid pool, and (e) computing the volume of the molten metal liquid. 3 figures.

Method of measuring a liquid pool volume

DOEpatents

Garcia, Gabe V.; Carlson, Nancy M.; Donaldson, Alan D.

1991-01-01

A method of measuring a molten metal liquid pool volume and in particular molten titanium liquid pools, including the steps of (a) generating an ultrasonic wave at the surface of the molten metal liquid pool, (b) shining a light on the surface of a molten metal liquid pool, (c) detecting a change in the frequency of light, (d) detecting an ultrasonic wave echo at the surface of the molten metal liquid pool, and (e) computing the volume of the molten metal liquid.

Process control of GMAW by detection of discontinuities in the molten weld pool

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carlson, N.M.; Kunerth, D.C.; Johnson, J.A.

1988-01-01

The use of ultrasonic sensors to detect discontinuities associated with the molten pool is one phase of a project to automate the welding process. In this work, ultrasonic sensors were used to interrogate the region around the molten/solid interface during gas metal arc welding (GMAW). The ultrasonic echoes from the interface and the molten pool provide information about the quality of the fusion zone and the molten pool. This information can be sent to a controller that can vary the welding parameters to correct the process. Previously ultrasonic shear waves were used to determine if the geometry of the molten/solidmore » interface was indicative of an acceptable weld. In this work, longitudinal waves were used to interrogate the molten weld pool for discontinuities. Unacceptable welding conditions that can result in porosity, incomplete penetration, or undercut were detected. 8 refs., 4 figs.« less

Electro Processing Research

NASA Technical Reports Server (NTRS)

1982-01-01

Electroprocessing which is concerned with fluid dynamics of the electroreduction process to determine how it may be modified to improve the quality of the deposit was studied. Experimental techniques are used in this research. These techniques include laser Schlieren photography, laser Doppler velocimetry, and frequency spectrum analysis. Projects involve fluid flow studies of zinc plating in aqueous and molten salt electrolytes, study of cell design for magnesium chlorides electrolysis, digital signal analysis of manganese electrodeposition in molten chlorides, and electroplating of molybdenum from low melting salts. It is anticipated that the use of refractory metals as constructed materials in engineering will increase. Their electrodeposition from molten salt electrolytes is important in the extraction metallurgy of refractory metals.

Thermal Stress and Heat Transfer Coefficient for Ceramics Stalk Having Protuberance Dipping into Molten Metal

NASA Astrophysics Data System (ADS)

Noda, Nao-Aki; Hendra; Li, Wenbin; Takase, Yasushi; Ogura, Hiroki; Higashi, Yusuke

Low pressure die casting is defined as a net shape casting technology in which the molten metal is injected at high speeds and pressure into a metallic die. The low pressure die casting process plays an increasingly important role in the foundry industry as a low-cost and high-efficiency precision forming technique. In the low pressure die casting process is that the permanent die and filling systems are placed over the furnace containing the molten alloy. The filling of the cavity is obtained by forcing the molten metal, by means of a pressurized gas, to rise into a ceramic tube having protuberance, which connects the die to the furnace. The ceramics tube, called stalk, has high temperature resistance and high corrosion resistance. However, attention should be paid to the thermal stress when the stalk having protuberance is dipped into the molten aluminum. It is important to reduce the risk of fracture that may happen due to the thermal stresses. In this paper, thermo-fluid analysis is performed to calculate surface heat transfer coefficient. The finite element method is applied to calculate the thermal stresses when the stalk having protuberance is dipped into the crucible with varying dipping speeds. It is found that the stalk with or without protuberance should be dipped into the crucible slowly to reduce the thermal stress.

Solidification in direct metal deposition by LENS processing

NASA Astrophysics Data System (ADS)

Hofmeister, William; Griffith, Michelle

2001-09-01

Thermal imaging and metallographic analysis were used to study Laser Engineered Net Shaping (LENS™) processing of 316 stainless steel and H13 tool steel. The cooling rates at the solid-liquid interface were measured over a range of conduction conditions. The length scale of the molten zone controls cooling rates during solidification in direct metal deposition. In LENS processing, the molten zone ranges from 0.5 mm in length to 1.5 mm, resulting in cooling rates at the solid-liquid interface ranging from 200 6,000 Ks-1.

CeO2-Y2O3-ZrO2 Membrane with Enhanced Molten Salt Corrosion Resistance for Solid Oxide Membrane (SOM) Electrolysis Process

NASA Astrophysics Data System (ADS)

Zou, Xingli; Li, Xin; Shen, Bin; Lu, Xionggang; Xu, Qian; Zhou, Zhongfu; Ding, Weizhong

2017-02-01

Innovative CeO2-Y2O3-ZrO2 membrane has been successfully developed and used in the solid oxide membrane (SOM) electrolysis process for green metallic materials production. The x mol pct ceria/(8- x) mol pct yttria-costabilized zirconia ( xCe(8- x)YSZ, x = 0, 1, 4, or 7) membranes have been fabricated and investigated as the membrane-based inert anodes to control the SOM electroreduction process in molten salt. The characteristics of these fabricated xCe(8- x)YSZ membranes including their corrosion resistances in molten salt and their degradation mechanisms have been systematically investigated and compared. The results show that the addition of ceria in the YSZ-based membrane can inhibit the depletion of yttrium during the SOM electrolysis, which thus makes the ceria-reinforced YSZ-based membranes possess enhanced corrosion resistances to molten salt. The ceria/yttria-costabilized zirconia membranes can also provide reasonable oxygen ion conductivity during electrolysis. Further investigation shows that the newly modified 4Ce4YSZ ceramic membrane has the potential to be used as novel inert SOM anode for the facile and sustainable production of metals/alloys/composites materials such as Si, Ti5Si3, TiC, and Ti5Si3/TiC from their metal oxides precursors in molten CaCl2.

Method for continuously recovering metals using a dual zone chemical reactor

DOEpatents

Bronson, Mark C.

1995-01-01

A dual zone chemical reactor continuously processes metal-containing materials while regenerating and circulating a liquid carrier. The starting materials are fed into a first reaction zone of a vessel containing a molten salt carrier. The starting materials react to form a metal product and a by-product that dissolves in the molten salt that flows to a second reaction zone in the reaction vessel. The second reaction zone is partitioned from, but in fluid communication with, the first reaction zone. The liquid carrier continuously circulates along a pathway between the first reaction zone and the second reaction zone. A reactive gas is introduced into the second reaction zone to react with the reaction by-product to generate the molten salt. The metal product, the gaseous waste products, and the excess liquid carrier are removed without interrupting the operation of the reactor. The design of the dual zone reactor can be adapted to combine a plurality of liquid carrier regeneration zones in a multiple dual zone chemical reactor for production scale processing.

Crucible cast from beryllium oxide and refractory cement is impervious to flux and molten metal

NASA Technical Reports Server (NTRS)

Jastrzebski, Z. D.

1966-01-01

Crucible from a mixture of a beryllium oxide aggregate and hydraulic refractory cement, and coated with an impervious refractory oxide will not deteriorate in the presence of fused salt- molten metal mixtures such as uranium- magnesium-zinc-halide salt systems. Vessels cast by this process are used in the flux reduction of oxides of thorium and uranium.

Porous membrane electrochemical cell for uranium and transuranic recovery from molten salt electrolyte

DOEpatents

Willit, James L [Ratavia, IL

2007-09-11

An improved process and device for the recovery of the minor actinides and the transuranic elements (TRU's) from a molten salt electrolyte. The process involves placing the device, an electrically non-conducting barrier between an anode salt and a cathode salt. The porous barrier allows uranium to diffuse between the anode and cathode, yet slows the diffusion of uranium ions so as to cause depletion of uranium ions in the catholyte. This allows for the eventual preferential deposition of transuranics present in spent nuclear fuel such as Np, Pu, Am, Cm. The device also comprises an uranium oxidation anode. The oxidation anode is solid uranium metal in the form of spent nuclear fuel. The spent fuel is placed in a ferric metal anode basket which serves as the electrical lead or contact between the molten electrolyte and the anodic uranium metal.

Porous membrane electrochemical cell for uranium and transuranic recovery from molten salt electrolyte

DOEpatents

Willit, James L [Batavia, IL

2010-09-21

An improved process and device for the recovery of the minor actinides and the transuranic elements (TRU's) from a molten salt electrolyte. The process involves placing the device, an electrically non-conducting barrier between an anode salt and a cathode salt. The porous barrier allows uranium to diffuse between the anode and cathode, yet slows the diffusion of uranium ions so as to cause depletion of uranium ions in the catholyte. This allows for the eventual preferential deposition of transuranics present in spent nuclear fuel such as Np, Pu, Am, Cm. The device also comprises an uranium oxidation anode. The oxidation anode is solid uranium metal in the form of spent nuclear fuel. The spent fuel is placed in a ferric metal anode basket which serves as the electrical lead or contact between the molten electrolyte and the anodic uranium metal.

Purification of alkali metal nitrates

DOEpatents

Fiorucci, Louis C.; Gregory, Kevin M.

1985-05-14

A process is disclosed for removing heavy metal contaminants from impure alkali metal nitrates containing them. The process comprises mixing the impure nitrates with sufficient water to form a concentrated aqueous solution of the impure nitrates, adjusting the pH of the resulting solution to within the range of between about 2 and about 7, adding sufficient reducing agent to react with heavy metal contaminants within said solution, adjusting the pH of the solution containing reducing agent to effect precipitation of heavy metal impurities and separating the solid impurities from the resulting purified aqueous solution of alkali metal nitrates. The resulting purified solution of alkali metal nitrates may be heated to evaporate water therefrom to produce purified molten alkali metal nitrate suitable for use as a heat transfer medium. If desired, the purified molten form may be granulated and cooled to form discrete solid particles of alkali metal nitrates.

Aluminum reference electrode

DOEpatents

Sadoway, Donald R.

1988-01-01

A stable reference electrode for use in monitoring and controlling the process of electrolytic reduction of a metal. In the case of Hall cell reduction of aluminum, the reference electrode comprises a pool of molten aluminum and a solution of molten cryolite, Na.sub.3 AlF.sub.6, wherein the electrical connection to the molten aluminum does not contact the highly corrosive molten salt solution. This is accomplished by altering the density of either the aluminum (decreasing the density) or the electrolyte (increasing the density) so that the aluminum floats on top of the molten salt solution.

SEPARATION OF PLUTONIUM FROM URANIUM

DOEpatents

Feder, H.M.; Nuttall, R.L.

1959-12-15

A process is described for extracting plutonium from powdered neutron- irradiated urarium metal by contacting the latter, while maintaining it in the solid form, with molten magnesium which takes up the plutonium and separating the molten magnesium from the solid uranium.

Metal Oxide Solubility and Molten Salt Corrosion.

DTIC Science & Technology

1982-03-29

METAL OXIDE SOLUBILITY AND MOLTEN SALT CORROSION .(U) MAR 82 K H STERN UNCLASSI E DL R L-4772NL EL .2. MICROCOPY RESOLUTION TEST CHART NATIONAL BURALU...21 l 7 3 ..... l DTIC NSPECT I" ’I cCPY INSECE( METAL OXIDE SOLUBILITY AND MOLTEN SALT CORROSION I. INTRODUCTION Molten ...discussed in terms of its importance to the understanding of molten salt corrosion . II. PROTECTIVE COATINGS Since most structural metals and alloys are

Compatibility of molten salts with advanced solar dynamic receiver materials

NASA Technical Reports Server (NTRS)

Jaworske, D. A.; Perry, W. D.

1989-01-01

Metal-coated graphite fibers are being considered as a thermal conductivity enhancement filler material for molten salts in solar dynamic thermal energy storage systems. The successful metal coating chosen for this application must exhibit acceptable wettability and must be compatible with the molten salt environment. Contact angle values between molten lithium fluoride and several metal, metal fluoride, and metal oxide substrates have been determined at 892 C using a modification of the Wilhelmy plate technique. Reproducible contact angles with repeated exposure to the molten LiF indicated compatibility.

Electrochemical cell utilizing molten alkali metal electrode-reactant

DOEpatents

Virkar, Anil V.; Miller, Gerald R.

1983-11-04

An improved electrochemical cell comprising an additive-modified molten alkali metal electrode-reactant and/or electrolyte is disclosed. Various electrochemical cells employing a molten alkali metal, e.g., sodium, electrode in contact with a cationically conductive ceramic membrane experience a lower resistance and a lower temperature coefficient of resistance whenever small amounts of selenium are present at the interface of the electrolyte and the molten alkali metal. Further, cells having small amounts of selenium present at the electrolyte-molten metal interface exhibit less degradation of the electrolyte under long term cycling conditions.

Lithium Assisted “Dissolution–Alloying” Synthesis of Nanoalloys from Individual Bulk Metals

DOE Office of Scientific and Technical Information (OSTI.GOV)

Barkholtz, Heather M.; Gallagher, James R.; Li, Tao

2016-04-12

We report new fundamental chemistry involved in the synthesis of bimetallic nanoalloys via dissolving the pure bulk transition metals in molten lithium. It is revealed at the atomic level that when two pure bulk transition metals such as Pd and Pt are placed in molten lithium (similar to 200 degrees C), they undergo a dissolution process in which the metal-metal bonds in pure bulk transition metals are completely ruptured, which results in the existence of individual Pd and Pt atoms surrounded by lithium atoms, as is evident by synchrotron X-ray adsorption techniques. Then, upon the conversion of metal lithium tomore » LiOH in humid air, the Pd and Pt atoms undergo an alloying process to aggregate into nanoalloys. This method was further expanded to include PdZn, which is notoriously difficult to prepare via traditional nanoalloy synthesis methods due to the easily oxidizable Zn component. The constantly reducing environment of metallic Li allowed for preparation of PdZn nanoalloys with minimal Zn oxidation via dissolution-alloying of individual bulk transition metals in molten lithium. Additionally, this lithium assisted "dissolution-alloying" method bypasses many complications intrinsic to conventional ion reduction-based nanoalloy synthesis including the necessity of ligated metal ions, the use of proper reducing agents and dispersing surfactants, and the presence of segregated phases due to different reduction potentials of the constituent metal ions.« less

Lithium assisted “dissolution–alloying” synthesis of nanoalloys from individual bulk metals

DOE PAGES

Barkholtz, Heather M.; Gallagher, James R.; Li, Tao; ...

2016-03-27

Here, we report new fundamental chemistry involved in the synthesis of bimetallic nanoalloys via dissolving the pure bulk transition metals in molten lithium. It is revealed at the atomic level that when two pure bulk transition metals such as Pd and Pt are placed in molten lithium (~200°C), they undergo a dissolution process in which the metal-metal bonds in pure bulk transition metals are completely ruptured, resulting in the existence of individual Pd and Pt atoms surrounded by lithium atoms, as is evident by synchrotron Xray adsorption techniques. Then, upon the conversion of metal lithium to LiOH in humid air,more » the Pd and Pt atoms undergo an alloying process, to aggregate into nanoalloys. This method was further expanded to include PdZn, which is notoriously difficult to prepare via traditional nanoalloy synthesis methods due to the easily oxidizable Zn component. The constantly reducing environment of metallic Li allowed for preparation of PdZn nanoalloys with minimal Zn oxidation via dissolution-alloying of individual bulk transition metals in molten lithium. Additionally, this lithium assisted “dissolutionalloying” method bypasses many complications intrinsic to conventional ion reductionbased nanoalloy synthesis including the necessity of ligated metal ions, the use of proper reducing agents and dispersing surfactants, and the presence of segregated phases due to different reduction potentials of the constituent metal ions.« less

Oxidation of hydrogen halides to elemental halogens with catalytic molten salt mixtures

DOEpatents

Rohrmann, Charles A.

1978-01-01

A process for oxidizing hydrogen halides by means of a catalytically active molten salt is disclosed. The subject hydrogen halide is contacted with a molten salt containing an oxygen compound of vanadium and alkali metal sulfates and pyrosulfates to produce an effluent gas stream rich in the elemental halogen. The reduced vanadium which remains after this contacting is regenerated to the active higher valence state by contacting the spent molten salt with a stream of oxygen-bearing gas.

High-bandwidth continuous-flow arc furnace

DOEpatents

Hardt, David E.; Lee, Steven G.

1996-01-01

A high-bandwidth continuous-flow arc furnace for stream welding applications includes a metal mass contained in a crucible having an orifice. A power source charges an electrode for generating an arc between the electrode and the mass. The arc heats the metal mass to a molten state. A pressurized gas source propels the molten metal mass through the crucible orifice in a continuous stream. As the metal is ejected, a metal feeder replenishes the molten metal bath. A control system regulates the electrode current, shielding gas pressure, and metal source to provide a continuous flow of molten metal at the crucible orifice. Independent control over the electrode current and shield gas pressure decouples the metal flow temperature and the molten metal flow rate, improving control over resultant weld characteristics.

High-bandwidth continuous-flow arc furnace

DOEpatents

Hardt, D.E.; Lee, S.G.

1996-08-06

A high-bandwidth continuous-flow arc furnace for stream welding applications includes a metal mass contained in a crucible having an orifice. A power source charges an electrode for generating an arc between the electrode and the mass. The arc heats the metal mass to a molten state. A pressurized gas source propels the molten metal mass through the crucible orifice in a continuous stream. As the metal is ejected, a metal feeder replenishes the molten metal bath. A control system regulates the electrode current, shielding gas pressure, and metal source to provide a continuous flow of molten metal at the crucible orifice. Independent control over the electrode current and shield gas pressure decouples the metal flow temperature and the molten metal flow rate, improving control over resultant weld characteristics. 4 figs.

Recovery of Nickel from Nickel-Based Superalloy Scraps by Utilizing Molten Zinc

NASA Astrophysics Data System (ADS)

Yagi, Ryohei; Okabe, Toru H.

2017-02-01

With the purpose of developing a new process for recycling nickel (Ni) directly from superalloy scraps, a fundamental study on the extraction and separation of Ni was carried out using molten zinc (Zn) as the extraction medium. In order to examine the reaction between molten Zn and the Ni-based superalloy, superalloy samples and Zn shots were heated at 1173 K (900 °C) for 6 hours. After heating, the superalloy samples fully reacted with Zn and dissolved in molten Zn. The Zn-alloyed sample obtained by slow cooling consisted of two separated upper and lower phases. In the upper part of the sample, only Zn and the Zn-Ni alloys were found; in the lower part, an intermetallic alloy consisting of refractory metals such as rhenium (Re) and tantalum (Ta) was found. This result shows that Ni and refractory metals contained in the scrap can be separated by utilizing the density differences between the Zn-Ni alloy and the refractory metals in molten Zn. Vacuum treatment of the upper part of the Zn-alloyed sample at 1173 K (900 °C) reduced the concentration of Zn in the sample from 97.0 to 0.4 mass pct. After Zn removal, a Ni alloy containing Ni with a purity of 85.3 to 86.1 mass pct and negligible quantities (<0.1 mass pct) of Re and Ta was obtained. Moreover, recovered Zn metal after distillation had a purity of more than 99.9 mass pct. Therefore, this process could be an environmentally sound recycling process that can recover Ni from superalloy scraps without the consumption of Zn or the generation of toxic wastes solutions.

Two-zone countercurrent smelter system and process

DOEpatents

Cox, J.H.; Fruehan, R.J.; Elliott, J.F.

1995-01-03

A process for continuously smelting iron ore by use of coal to yield molten iron or semi-steel is disclosed. The process comprises the steps of establishing a melt covered by slag; inducing the slag and the molten iron to flow countercurrently to one another, toward opposite ends of the smelter; maintaining iron oxide-reducing conditions in that zone of the smelter towards which the slag flows; maintaining carbon-oxidizing conditions in that zone of the smelter towards which the molten iron flows; continuously or semicontinuously tapping the slag from the reducing zone end of the smelter; continuously or semicontinuously tapping the molten iron from the oxidizing zone end of the smelter; and adding to both zones iron ore, coal, oxygen, and flux at addition rates sufficient to keep the molten iron in the reducing zone substantially saturated with carbon, maintain in the slag being tapped an FeO content of about 5 weight percent or less, and maintain in the molten iron being tapped a carbon content of about 0.5 to 5 weight percent. A slag dam preferably is included in the smelter, to impede the backflow of the slag from the reducing zone to the oxidizing zone. A metal bath dam with one or more flow-through portals also is preferably used, submerged below the slag dam, to impede the backflow of the hot metal. 8 figures.

Two-zone countercurrent smelter system and process

DOEpatents

Cox, James H.; Fruehan, Richard J.; Elliott, deceased, John F.

1995-01-01

A process for continuously smelting iron ore by use of coal to yield molten iron or semi-steel is disclosed. The process comprises the steps of establishing a melt covered by slag; inducing the slag and the molten iron to flow countercurrently to one another, toward opposite ends of the smelter; maintaining iron oxide-reducing conditions in that zone of the smelter towards which the slag flows; maintaining carbon-oxidizing conditions in that zone of the smelter towards which the molten iron flows; continuously or semicontinuously tapping the slag from the reducing zone end of the smelter; continuously or semicontinuously tapping the molten iron from the oxidizing zone end of the smelter; and adding to both zones iron ore, coal, oxygen, and flux at addition rates sufficient to keep the molten iron in the reducing zone substantially saturated with carbon, maintain in the slag being tapped an FeO content of about 5 weight percent or less, and maintain in the molten iron being tapped a carbon content of about 0.5 to 5 weight percent. A slag dam preferably is included in the smelter, to impede the backflow of the slag from the reducing zone to the oxidizing zone. A metal bath dam with one or more flow-through portals also is preferably used, submerged below the slag dam, to impede the backflow of the hot metal.

Systems and Methods for Fabricating Objects Including Amorphous Metal Using Techniques Akin to Additive Manufacturing

NASA Technical Reports Server (NTRS)

Hofmann, Douglas (Inventor)

2017-01-01

Systems and methods in accordance with embodiments of the invention fabricate objects including amorphous metals using techniques akin to additive manufacturing. In one embodiment, a method of fabricating an object that includes an amorphous metal includes: applying a first layer of molten metallic alloy to a surface; cooling the first layer of molten metallic alloy such that it solidifies and thereby forms a first layer including amorphous metal; subsequently applying at least one layer of molten metallic alloy onto a layer including amorphous metal; cooling each subsequently applied layer of molten metallic alloy such that it solidifies and thereby forms a layer including amorphous metal prior to the application of any adjacent layer of molten metallic alloy; where the aggregate of the solidified layers including amorphous metal forms a desired shape in the object to be fabricated; and removing at least the first layer including amorphous metal from the surface.

Stabilization/solidification of radioactive salt waste by using xSiO2-yAl2O3-zP2O5 (SAP) material at molten salt state.

PubMed

Park, Hwan-Seo; Kim, In-Tae; Cho, Yong-Zun; Eun, Hee-Chul; Lee, Han-Soo

2008-12-15

The molten salt waste from the pyroprocess is one of the problematic wastes to directly apply a conventional process such as vitrification or ceramization. This study suggested a novel method using a reactive material for metal chlorides at a molten temperature of salt waste, and then converting them into manageable product at a high temperature. The inorganic composite, SAP (SiO2-Al2O3-P2O5), synthesized by a conventional sol-gel process has three or four distinctive domains that are bonded sequentially, Si-O-Si-O-A-O-P-O-P. The P-rich phase in the SAP composite is unstable for producing a series of reactive sites when in contact with a molten LiCl salt. After the reaction, metal aluminosilicate, metal aluminophosphate, metal phosphates and gaseous chlorines are generated. From this process, the volatile salt waste is stabilized and it is possible to apply a high temperature process. The reaction products were fabricated successfully by using a borosilicate glass with an arbitrary composition as a chemical binder. There was a low possibility for the valorization of radionuclides up to 1200 degrees C, based on the result of the thermo gravimetric analysis. The Cs and Sr leach rates by the PCT-A method were about 1 x 10(-3) g/(m2 day). For the final disposal of the problematic salt waste, this approach suggested the design concept of an effective stabilizer for metal chlorides and revealed the chemical route to the fabrication of monolithic wasteform by using a composite as an example. Using this method, we could obtain a higher disposal efficiency and lower waste volume, compared with the present immobilization methods.

Sidewall containment of liquid metal with vertical alternating magnetic fields

DOEpatents

Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.; Battles, James E.; Hull, John R.; Rote, Donald M.

1990-01-01

An apparatus for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel.

Aluminum reference electrode

DOEpatents

Sadoway, D.R.

1988-08-16

A stable reference electrode is described for use in monitoring and controlling the process of electrolytic reduction of a metal. In the case of Hall cell reduction of aluminum, the reference electrode comprises a pool of molten aluminum and a solution of molten cryolite, Na[sub 3]AlF[sub 6], wherein the electrical connection to the molten aluminum does not contact the highly corrosive molten salt solution. This is accomplished by altering the density of either the aluminum (decreasing the density) or the electrolyte (increasing the density) so that the aluminum floats on top of the molten salt solution. 1 fig.

SEPARATION OF METAL SALTS BY ADSORPTION

DOEpatents

Gruen, D.M.

1959-01-20

It has been found that certain metal salts, particularly the halides of iron, cobalt, nickel, and the actinide metals, arc readily absorbed on aluminum oxide, while certain other salts, particularly rare earth metal halides, are not so absorbed. Use is made of this discovery to separate uranium from the rare earths. The metal salts are first dissolved in a molten mixture of alkali metal nitrates, e.g., the eutectic mixture of lithium nitrate and potassium nitrate, and then the molten salt solution is contacted with alumina, either by slurrying or by passing the salt solution through an absorption tower. The process is particularly valuable for the separation of actinides from lanthanum-group rare earths.

Solid oxide membrane (SOM) process for ytterbium and silicon production from their oxides

NASA Astrophysics Data System (ADS)

Jiang, Yihong

The Solid oxide membrane (SOM) electrolysis is an innovative green technology that produces technologically important metals directly from their respective oxides. A yttria-stabilized zirconia (YSZ) tube, closed at one end is employed to separate the molten salt containing dissolved metal oxides from the anode inside the YSZ tube. When the applied electric potential between the cathode in the molten salt and the anode exceeds the dissociation potential of the desired metal oxides, oxygen ions in the molten salt migrate through the YSZ membrane and are oxidized at the anode while the dissolved metal cations in the flux are reduced to the desired metal at the cathode. Compared with existing metal production processes, the SOM process has many advantages such as one unit operation, less energy consumption, lower capital costs and zero carbon emission. Successful implementation of the SOM electrolysis process would provide a way to mitigate the negative environmental impact of the metal industry. Successful demonstration of producing ytterbium (Yb) and silicon (Si) directly from their respective oxides utilizing the SOM electrolysis process is presented in this dissertation. During the SOM electrolysis process, Yb2O3 was reduced to Yb metal on an inert cathode. The melting point of the supporting electrolyte (LiF-YbF3-Yb2O3) was determined by differential thermal analysis (DTA). Static stability testing confirmed that the YSZ tube was stable with the flux at operating temperature. Yb metal deposit on the cathode was confirmed by scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS). During the SOM electrolysis process for silicon production, a fluoride based flux based on BaF2, MgF2, and YF3 was engineered to serve as the liquid electrolyte for dissolving silicon dioxide. YSZ tube was used to separate the molten salt from an anode current collector in the liquid silver. Liquid tin was chosen as cathode to dissolve the reduced silicon during SOM electrolysis. After electrolysis, upon cooling, silicon crystals precipitated out from the Si-Sn liquid alloy. The presence of high-purity silicon crystals in the liquid tin cathode was confirmed by SEM/EDS. The fluoride based flux was also optimized to improve YSZ membrane stability for long-term use.

Electrochemical cell having an alkali-metal-nitrate electrode

DOEpatents

Roche, M.F.; Preto, S.K.

1982-06-04

A power-producing secondary electrochemical cell includes a molten alkali metal as the negative-electrode material and a molten-nitrate salt as the positive-electrode material. The molten material in the respective electrodes are separated by a solid barrier of alkali-metal-ion conducting material. A typical cell includes active materials of molten sodium separated from molten sodium nitrate and other nitrates in mixture by a layer of sodium ..beta..'' alumina.

Steel refining with an electrochemical cell

DOEpatents

Blander, M.; Cook, G.M.

1988-05-17

Apparatus is described for processing a metallic fluid containing iron oxide, container for a molten metal including an electrically conductive refractory disposed for contact with the molten metal which contains iron oxide, an electrolyte in the form of a basic slag on top of the molten metal, an electrode in the container in contact with the slag electrically separated from the refractory, and means for establishing a voltage across the refractory and the electrode to reduce iron oxide to iron at the surface of the refractory in contact with the iron oxide containing fluid. A process is disclosed for refining an iron product containing not more than about 10% by weight oxygen and not more than about 10% by weight sulfur, comprising providing an electrolyte of a slag containing one or more of calcium oxide, magnesium oxide, silica or alumina, providing a cathode of the iron product in contact with the electrolyte, providing an anode in contact with the electrolyte electrically separated from the cathode, and operating an electrochemical cell formed by the anode, the cathode and the electrolyte to separate oxygen or sulfur present in the iron product therefrom. 2 figs.

Method for continuously recovering metals using a dual zone chemical reactor

DOEpatents

Bronson, M.C.

1995-02-14

A dual zone chemical reactor continuously processes metal-containing materials while regenerating and circulating a liquid carrier. The starting materials are fed into a first reaction zone of a vessel containing a molten salt carrier. The starting materials react to form a metal product and a by-product that dissolves in the molten salt that flows to a second reaction zone in the reaction vessel. The second reaction zone is partitioned from, but in fluid communication with, the first reaction zone. The liquid carrier continuously circulates along a pathway between the first reaction zone and the second reaction zone. A reactive gas is introduced into the second reaction zone to react with the reaction by-product to generate the molten salt. The metal product, the gaseous waste products, and the excess liquid carrier are removed without interrupting the operation of the reactor. The design of the dual zone reactor can be adapted to combine a plurality of liquid carrier regeneration zones in a multiple dual zone chemical reactor for production scale processing. 6 figs.

Steel refining with an electrochemical cell

DOEpatents

Blander, M.; Cook, G.M.

1985-05-21

Disclosed is an apparatus for processing a metallic fluid containing iron oxide, container for a molten metal including an electrically conductive refractory disposed for contact with the molten metal which contains iron oxide, an electrolyte in the form of a basic slag on top of the molten metal, an electrode in the container in contact with the slag electrically separated from the refractory, and means for establishing a voltage across the refractory and the electrode to reduce iron oxide to iron at the surface of the refractory in contact with the iron oxide containing fluid. A process is disclosed for refining an iron product containing not more than about 10% by weight sulfur, comprising providing an electrolyte of a slag containing one or more of calcium oxide, magnesium oxide, silica or alumina, providing a cathode of the iron product in contact with the electrolyte, providing an anode in contact with the electrolyte electrically separated from the cathode, and operating an electrochemical cell formed by the anode, the cathode and the electrolyte to separate oxygen or sulfur present in the iron product therefrom.

Steel refining with an electrochemical cell

DOEpatents

Blander, Milton; Cook, Glenn M.

1988-01-01

Apparatus for processing a metallic fluid containing iron oxide, container for a molten metal including an electrically conductive refractory disposed for contact with the molten metal which contains iron oxide, an electrolyte in the form of a basic slag on top of the molten metal, an electrode in the container in contact with the slag electrically separated from the refractory, and means for establishing a voltage across the refractory and the electrode to reduce iron oxide to iron at the surface of the refractory in contact with the iron oxide containing fluid. A process is disclosed for refining an iron product containing not more than about 10% by weight oxygen and not more than about 10% by weight sulfur, comprising providing an electrolyte of a slag containing one or more of calcium oxide, magnesium oxide, silica or alumina, providing a cathode of the iron product in contact with the electrolyte, providing an anode in contact with the electrolyte electrically separated from the cathode, and operating an electrochemical cell formed by the anode, the cathode and the electrolyte to separate oxygen or sulfur present in the iron product therefrom.

Refractory lining for electrochemical cell

DOEpatents

Blander, Milton; Cook, Glenn M.

1987-01-01

Apparatus for processing a metallic fluid containing iron oxide, container for a molten metal including an electrically conductive refractory disposed for contact with the molten metal which contains iron oxide, an electrolyte in the form of a basic slag on top of the molten metal, an electrode in the container in contcat with the slag electrically separated from the refractory, and means for establishing a voltage across the refractory and the electrode to reduce iron oxide to iron at the surface of the refractory in contact with the iron oxide containing fluid. A process is disclosed for refining an iron product containing not more than about 10% by weight oxygen and not more than about 10% by weight sulfur, comprising providing an electrolyte of a slag containing one or more of calcium oxide, magnesium oxide, silica or alumina, providing a cathode of the iron product in contact with the electrolyte, providing an anode in contact with the electrolyte electrically separated from the cathode, and operating an electrochemical cell formed by the anode, the cathode and the electrolyte to separate oxygen or sulfur present in the iron product therefrom.

Molten salt applications in materials processing

NASA Astrophysics Data System (ADS)

Mishra, Brajendra; Olson, David L.

2005-02-01

The science of molten salt electrochemistry for electrowinning of reactive metals, such as calcium, and its in situ application in pyro-reduction has been described. Calcium electrowinning has been performed in a 5 10 wt% calcium oxide calcium chloride molten salt by the electrolytic dissociation of calcium oxide. This electrolysis requires the use of a porous ceramic sheath around the anode to keep the cathodically deposited calcium and the anodic gases separate. Stainless steel cathode and graphite anode have been used in the temperature range of 850 950 °C. This salt mixture is produced as a result of the direct oxide reduction (DOR) of reactive metal oxides by calcium in a calcium chloride bath. The primary purpose of this process is to recover the expensive calcium reductant and to recycle calcium chloride. Experimental data have been included to justify the suitability as well as limitations of the electrowinning process. Transport of oxygen ions through the sheath is found to be the rate controlling step. Under the constraints of the reactor design, a calcium recovery rate of approx. 150 g/h was achieved. Feasibility of a process to produce metals by pyrometallurgical reduction, using the calcium reductant produced electrolytically within the same reactor, has been shown in a hybrid process. Several processes are currently under investigation to use this electrowon calcium for in situ reduction of metal oxides.

Diffusion mechanism in molten salt baths during the production of carbide coatings via thermal reactive diffusion

NASA Astrophysics Data System (ADS)

Ghadi, Aliakbar; Saghafian, Hassan; Soltanieh, Mansour; Yang, Zhi-gang

2017-12-01

The diffusion mechanism of carbide-forming elements from a molten salt bath to a substrate surface was studied in this research, with particular focus on the processes occurring in the molten bath at the time of coating. Metal, oxide, and metal-oxide baths were investigated, and the coating process was performed on H13 steel substrates. Scanning electron microscopy and electron-probe microanalysis were used to study the coated samples and the quenched salt bath. The thickness of the carbide coating layer was 6.5 ± 0.5, 5.2 ± 0.5, or 5.7 ± 0.5 μm depending on whether it was deposited in a metal, oxide, or metal-oxide bath, respectively. The phase distribution of vanadium-rich regions was 63%, 57%, and 74% of the total coating deposited in metal, oxide, and metal-oxide baths, respectively. The results obtained using the metal bath indicated that undissolved suspended metal particles deposited onto the substrate surface. Then, carbon subsequently diffused to the substrate surface and reacted with the metal particles to form the carbides. In the oxide bath, oxide powders dissolved in the bath with or without binding to the oxidative structure (Na2O) of borax; they were then reduced by aluminum and converted into metal particles. We concluded that, in the metal and oxide baths, the deposition of metal particles onto the sample surface is an important step in the formation of the coating.

Molten metal containment vessel with rare earth oxysulfide protective coating thereon and method of making same

DOEpatents

Krikorian, Oscar H.; Curtis, Paul G.

1992-01-01

An improved molten metal containment vessel is disclosed in which wetting of the vessel's inner wall surfaces by molten metal is inhibited by coating at least the inner surfaces of the containment vessel with one or more rare earth oxysulfide or rare earth sulfide compounds to inhibit wetting and or adherence by the molten metal to the surfaces of the containment vessel.

Castable cements to prevent corrosion of metals in molten salts

DOE PAGES

Gomez-Vidal, Judith C.; Morton, E.

2016-04-22

Castable cements on metals form a protective barrier that is able to prevent permeation of molten salts towards metallic surfaces. Silica-based castable cements are capable of protecting containment metallic alloys from the corrosive attack of molten chlorides at temperatures as high as 650 °C. Boron nitride (BN) blocking the pores in the cured cement prevents permeation of the molten chloride towards the metal surface. The cements tested are not chemically stable in molten carbonates, because the bonding components dissolved into molten carbonates salt. The corrosion rate is 7.72±0.32 mm/year for bare stainless steel 347 in molten eutectic NaCl – 65.58more » wt% LiCl at 650 °C, which is the baseline used for determining how well the cement protects the metallic surfaces from corrosion. In particular the metal fully encapsulated with Aremco 645-N with pores filled with boron nitride immersed in molten eutectic NaCl – 65.58 wt% LiCl at 650 °C shows a corrosion rate of 9E-04 mm/year. Here, the present study gives initial corrosion rates. Long-term tests are required to determine if Aremco 645-N with BN coating on metal has long term chemical stability for blocking salt permeation through coating pores.« less

Sidewall containment of liquid metal with vertical alternating magnetic fields

DOEpatents

Lari, R.J.; Praeg, W.F.; Turner, L.R.; Battles, J.E.; Hull, J.R.; Rote, D.M.

1990-12-04

An apparatus is disclosed for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel. 9 figs.

Sidewall containment of liquid metal with vertical alternating magnetic fields

DOEpatents

Lari, R.J.; Praeg, W.F.; Turner, L.R.; Battles, J.E.; Hull, J.R.; Rote, D.M.

1988-06-17

An apparatus for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent to the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel. 8 figs.

Core formation in the shergottite parent body and comparison with the earth

DOE Office of Scientific and Technical Information (OSTI.GOV)

Treiman, A.H.; Jones, J.H.; Drake, M.J.

1987-03-30

The mantle of the shergottite parent body (SPB) is depleted relative to the bulk SPB in siderophile and chalcophile elements; these elements are inferred to reside in the SPB's core. Our chemical model of these depletions rests on a physically plausible process of segregation of partially molten metal form partially molten silicates as the SPB grows and is heated above silicate and metallic solidi during accretion. Metallic and silicate phases equilibrate at low pressures as new material is accreted to the SPB surface. Later movement of the metallic phases to the planet's center is so rapid that high-pressure equilibration ismore » insignificant. Partitioning of siderophile and chalcophile elements among solid and liquid metal and silicate determines their abundances in the SPB mantle. Using partition coefficients and the SPB mantle composition determined in earlier studies, we model the abundances of Ag, Au, Co, Ga, Mo, Ni, P, Re, S, and W with free parameters being oxygen fugacity, proportion of solid metal formed, proportion of metallic liquid formed, and proportion of silicate that is molten.« less

Molten metal holder furnace and casting system incorporating the molten metal holder furnace

DOEpatents

Kinosz, Michael J.; Meyer, Thomas N.

2003-02-11

A bottom heated holder furnace (12) for containing a supply of molten metal includes a storage vessel (30) having sidewalls (32) and a bottom wall (34) defining a molten metal receiving chamber (36). A furnace insulating layer (42) lines the molten metal receiving chamber (36). A thermally conductive heat exchanger block (54) is located at the bottom of the molten metal receiving chamber (36) for heating the supply of molten metal. The heat exchanger block (54) includes a bottom face (65), side faces (66), and a top face (67). The heat exchanger block (54) includes a plurality of electrical heaters (70) extending therein and projecting outward from at least one of the faces of the heat exchanger block (54), and further extending through the furnace insulating layer (42) and one of the sidewalls (32) of the storage vessel (30) for connection to a source of electrical power. A sealing layer (50) covers the bottom face (65) and side faces (66) of the heat exchanger block (54) such that the heat exchanger block (54) is substantially separated from contact with the furnace insulating layer (42).

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gordon, John Howard; Alvare, Javier

Alkali metals and sulfur may be recovered from alkali monosulfide and polysulfides in an electrolytic process that utilizes an electrolytic cell having an alkali ion conductive membrane. An anolyte solution includes an alkali monosulfide, an alkali polysulfide, or a mixture thereof and a solvent that dissolves elemental sulfur. A catholyte includes molten alkali metal. Applying an electric current oxidizes sulfide and polysulfide in the anolyte compartment, causes alkali metal ions to pass through the alkali ion conductive membrane to the catholyte compartment, and reduces the alkali metal ions in the catholyte compartment. Liquid sulfur separates from the anolyte solution andmore » may be recovered. The electrolytic cell is operated at a temperature where the formed alkali metal and sulfur are molten.« less

Roles of Cationic and Elemental Calcium in the Electro-Reduction of Solid Metal Oxides in Molten Calcium Chloride

NASA Astrophysics Data System (ADS)

Qiu, Guohong; Jiang, Kai; Ma, Meng; Wang, Dihua; Jin, Xianbo; Chen, George Z.

2007-06-01

Previous work, mainly from this research group, is re-visited on electrochemical reduction of solid metal oxides, in the form of compacted powder, in molten CaCl2, aiming at further understanding of the roles of cationic and elemental calcium. The discussion focuses on six aspects: 1.) debate on two mechanisms proposed in the literature, i. e. electro-metallothermic reduction and electro-reduction (or electro-deoxidation), for the electrolytic removal of oxygen from solid metals or metal oxides in molten CaCl2; 2.) novel metallic cavity working electrodes for electrochemical investigations of compacted metal oxide powders in high temperature molten salts assisted by a quartz sealed Ag/AgCl reference electrode (650 ºC- 950 ºC); 3.) influence of elemental calcium on the background current observed during electrolysis of solid metal oxides in molten CaCl2; 4.) electrochemical insertion/ inclusion of cationic calcium into solid metal oxides; 5.) typical features of cyclic voltammetry and chronoamperometry (potentiostatic electrolysis) of metal oxide powders in molten CaCl2; and 6.) some kinetic considerations on the electrolytic removal of oxygen.

METAL PRODUCTION AND CASTING

DOEpatents

Magel, T.T.

1958-03-01

This patent covers a method and apparatus for collecting the molten metal produced by high temperature metal salt reduction. It consists essentially of subjecting the reaction vessel to centrifugal force in order to force the liberatcd molten metal into a coherent molten mass, and allowing it to solidify there. The apparatus is particularly suitable for use with small quantities of rare metals.

Molten salts and energy related materials.

PubMed

Fray, Derek

2016-08-15

Molten salts have been known for centuries and have been used for the extraction of aluminium for over one hundred years and as high temperature fluxes in metal processing. This and other molten salt routes have gradually become more energy efficient and less polluting, but there have been few major breakthroughs. This paper will explore some recent innovations that could lead to substantial reductions in the energy consumed in metal production and in carbon dioxide production. Another way that molten salts can contribute to an energy efficient world is by creating better high temperature fuel cells and novel high temperature batteries, or by acting as the medium that can create novel materials that can find applications in high energy batteries and other energy saving devices, such as capacitors. Carbonate melts can be used to absorb carbon dioxide, which can be converted into C, CO and carbon nanoparticles. Molten salts can also be used to create black silicon that can absorb more sunlight over a wider range of wavelengths. Overall, there are many opportunities to explore for molten salts to play in an efficient, low carbon world.

Use of steel and tantalum apparatus for molten Cd-Mg-Zn alloys

NASA Technical Reports Server (NTRS)

Bennett, G. A.; Burris, L., Jr.; Kyle, M. L.; Nelson, P. A.

1966-01-01

Steel and tantalum apparatus contains various ternary alloys of cadmium, zinc, and magnesium used in pyrochemical processes for the recovery of uranium-base reactor fuels. These materials exhibit good corrosion resistance at the high temperatures necessary for fuel separation in liquid metal-molten salt solvents.

Recirculating Molten Metal Supply System And Method

DOEpatents

Kinosz, Michael J.; Meyer, Thomas N.

2003-07-01

The melter furnace includes a heating chamber (16), a pump chamber (18), a degassing chamber (20), and a filter chamber (22). The pump chamber (18) is located adjacent the heating chamber (16) and houses a molten metal pump (30). The degassing chamber (20) is located adjacent and in fluid communication with the pump chamber (18), and houses a degassing mechanism (36). The filter chamber (22) is located adjacent and in fluid communication with the degassing chamber (20). The filter chamber (22) includes a molten metal filter (38). The melter furnace (12) is used to supply molten metal to an externally located holder furnace (14), which then recirculates molten metal back to the melter furnace (12).

Presence of Li clusters in molten LiCl-Li

DOE PAGES

Merwin, Augustus; Phillips, William C.; Williamson, Mark A.; ...

2016-05-05

Molten mixtures of lithium chloride and metallic lithium are of significant interest in various metal oxide reduction processes. These solutions have been reported to exhibit seemingly anomalous physical characteristics that lack a comprehensive explanation. ln the current work, the physical chemistry of molten solutions of lithium chloride and metallic lithium, with and without lithium oxide, was investigated using in situ Raman spectroscopy. The Raman spectra obtained from these solutions were in agreement with the previously reported spectrum of the lithium cluster, Li 8. Furthermore, this observation is indicative of a nanofluid type colloidal suspension of Li 8, in a moltenmore » salt matrix. It is suggested that the formation and suspension of lithium clusters in lithium chloride is the cause of various phenomena exhibited by these solutions that were previously unexplainable.« less

Fragment structure from vapor explosions during the impact of molten metal droplets into a liquid pool

NASA Astrophysics Data System (ADS)

Kouraytem, Nadia; Li, Er Qiang; Vakarelski, Ivan Uriev; Thoroddsen, Sigurdur

2015-11-01

High-speed video imaging is used in order to look at the impact of a molten metal drop falling into a liquid pool. The interaction regimes are three: film boiling, nucleate boiling or vapor explosion. Following the vapor explosion, the metal fragments and different textures are observed. It was seen that, using a tin alloy, a porous structure results whereas using a distinctive eutectic metal, Field's metal, micro beads are formed. Different parameters such as the metal type, molten metal temperature, pool surface tension and pool boiling temperature have been altered in order to assess the role they play on the explosion dynamics and the molten metal's by product.

Method for hydrocracking a heavy polynuclear hydrocarbonaceous feedstock in the presence of a molten metal halide catalyst

DOEpatents

Gorin, Everett

1981-01-01

A method for hydrocracking a heavy polynuclear hydrocarbonaceous feedstock to produce lighter hydrocarbon fuels by contacting the feedstock with hydrogen in the presence of a molten metal halide catalyst, the method comprising: mixing the feedstock with a heavy naphtha fraction which has an initial boiling point from about 100.degree. to about 160.degree. C. with a boiling point difference between the initial boiling point and the final boiling point of no more than about 50.degree. C. to produce a mixture; thereafter contacting the mixture with partially spent molten metal halide and hydrogen under temperature and pressure conditions so that the temperature is near the critical temperature of the heavy naphtha fraction; separating at least a portion of the heavy naphtha fraction and lighter hydrocarbon fuels from the partially spent molten metal halide, unreacted feedstock and reaction products; thereafter contacting the partially spent molten metal halide, unreacted feedstock and reaction products with hydrogen and fresh molten metal halide in a hydrocracking zone to produce additional lighter hydrocarbon fuels and separating at least a major portion of the lighter hydrocarbon fuels from the spent molten metal halide.

Continuous production of granular or powder Ti, Zr and Hf or their alloy products

DOEpatents

White, Jack C.; Oden, Laurance L.

1993-01-01

A continuous process for producing a granular metal selected from the group consisting of Ti, Zr or Hf under conditions that provide orderly growth of the metal free of halide inclusions comprising: a) dissolving a reducing metal selected from the group consisting of Na, Mg, Li or K in their respective halide salts to produce a reducing molten salt stream; b) preparing a second molten salt stream containing the halide salt of Ti, Zr or Hf; c) mixing and reacting the two molten streams of steps a) and b) in a continuous stirred tank reactor; d) wherein steps a) through c) are conducted at a temperature range of from about 800.degree. C. to about 1100.degree. C. so that a weight percent of equilibrium solubility of the reducing metal in its respective halide salt varies from about 1.6 weight percent at about 900.degree. C. to about 14.4 weight percent at about 1062.degree. C.; and wherein a range of concentration of the halide salt of Ti, Zn or Hf in molten halides of Na, Mg, Li or K is from about 1 to about 5 times the concentration of Na, Mg, Li or K; e) placing the reacted molten stream from step c) in a solid-liquid separator to recover an impure granular metal product by decantation, centrifugation, or filtration; and f) removing residual halide salt impurity by vacuum evaporator or inert gas sweep at temperatures from about 850.degree. C. to 1000.degree. C. or cooling the impure granular metal product to ambient temperature and water leaching off the residual metal halide salt.

Mathematical modelling of convective processes in a weld pool under electric arc surfacing

NASA Astrophysics Data System (ADS)

Sarychev, V. D.; Granovskii, A. Yu; Nevskii, S. A.; Konovalov, S. V.

2017-01-01

The authors develop the mathematical model of convective processes in a molten pool under electric arc surfacing with flux-cored wire. The model is based on the ideas of how convective flows appear due to temperature gradient and action of electromagnetic forces. Influence of alloying elements in the molten metal was modeled as a non-linear dependence of surface tension upon temperature. Surface tension and its temperature coefficient were calculated according to the electron density functional method with consideration to asymmetric electron distribution at the interface “molten metal / shielding gas”. Simultaneous solution of Navier-Stokes and Maxwell equations according to finite elements method with consideration to the moving heat source at the interface showed that there is a multi-vortex structure in the molten metal. This structure gives rise to a downward heat flux which, at the stage of heating, moves from the centre of the pool and stirs it full width. At the cooling stage this flux moves towards the centre of the pool and a single vortex is formed near the symmetry centre. This flux penetration is ∼ 10 mm. Formation of the downward heat flux is determined by sign reversal of the temperature coefficient of surface tension due to the presence of alloying elements.

Feet sunk in molten aluminium: The burn and its prevention.

PubMed

Alonso-Peña, David; Arnáiz-García, María Elena; Valero-Gasalla, Javier Luis; Arnáiz-García, Ana María; Campillo-Campaña, Ramón; Alonso-Peña, Javier; González-Santos, Jose María; Fernández-Díaz, Alaska Leonor; Arnáiz, Javier

2015-08-01

Nowadays, despite improvements in safety rules and inspections in the metal industry, foundry workers are not free from burn accidents. Injuries caused by molten metals include burns secondary to molten iron, aluminium, zinc, copper, brass, bronze, manganese, lead and steel. Molten aluminium is one of the most common causative agents of burns (60%); however, only a few publications exist concerning injuries from molten aluminium. The main mechanisms of lesion from molten aluminium include direct contact of the molten metal with the skin or through safety apparel, or when the metal splash burns through the pants and rolls downward along the leg. Herein, we report three cases of deep dermal burns after 'soaking' the foot in liquid aluminium and its evolutive features. This paper aims to show our experience in the management of burns due to molten aluminium. We describe the current management principles and the key features of injury prevention. Copyright © 2014 Elsevier Ltd and ISBI. All rights reserved.

Closed cell metal foam method

DOEpatents

Patten, James W.

1978-01-01

Foamed metals and metal alloys which have a closed cellular structure are prepared by heating a metal body containing entrapped inert gas uniformly distributed throughout to a temperature above the melting point of the metal and maintaining the body at this temperature a period of time sufficient to permit the entrapped gas to expand, forming individual cells within the molten metal, thus expanding and foaming the molten metal. After cell formation has reached the desired amount, the foamed molten metal body is cooled to below the melting temperature of the metal. The void area or density of the foamed metal is controlled by predetermining the amount of inert gas entrapped in the metal body and by the period of time the metal body is maintained in the molten state. This method is useful for preparing foamed metals and metal alloys from any metal or other material of which a body containing entrapped inert gas can be prepared.

Orbital foamed material extruder

NASA Technical Reports Server (NTRS)

Tucker, Dennis S. (Inventor)

2009-01-01

This invention is a process for producing foamed material in space comprising the steps of: rotating the material to simulate the force of gravity; heating the rotating material until it is molten; extruding the rotating, molten material; injecting gas into the extruded, rotating, molten material to produce molten foamed material; allowing the molten foamed material to cool to below melting temperature to produce the foamed material. The surface of the extruded foam may be heated to above melting temperature and allowed to cool to below melting temperature. The extruded foam may also be cut to predetermined length. The starting material may be metal or glass. Heating may be accomplished by electrical heating elements or by solar heating.

Thermal sprayed composite melt containment tubular component and method of making same

DOEpatents

Besser, Matthew F.; Terpstra, Robert L.; Sordelet, Daniel J.; Anderson, Iver E.

2002-03-19

A tubular thermal sprayed melt containment component for transient containment of molten metal or alloy wherein the tubular member includes a thermal sprayed inner melt-contacting layer for contacting molten metal or alloy to be processed, a thermal sprayed heat-generating layer deposited on the inner layer, and an optional thermal sprayed outer thermal insulating layer. The thermal sprayed heat-generating layer is inductively heated as a susceptor of an induction field or electrical resistively heated by passing electrical current therethrough. The tubular thermal sprayed melt containment component can comprise an elongated melt pour tube of a gas atomization apparatus where the melt pour tube supplies molten material from a crucible to an underlying melt atomization nozzle.

Method and apparatus for planar drag strip casting

DOEpatents

Powell, John C.; Campbell, Steven L.

1991-01-01

The present invention is directed to an improved process and apparatus for strip casting. The combination of a planar flow casting nozzle positioned back from the top dead center position with an attached nozzle extension, provides an increased level of casting control and quality. The nozzle extension provides a means of containing the molten pool above the rotating substrate to increase the control of molten metal at the edges of the strip and increase the range of coating thicknesses which may be produced. The level of molten metal in the containment means is regulated to be above the level of melt supplying the casting nozzle which produces a condition of planar drag flow with the casting substrate prior to solidification.

Method and apparatus for planar drag strip casting

DOEpatents

Powell, J.C.; Campbell, S.L.

1991-11-12

The present invention is directed to an improved process and apparatus for strip casting. The combination of a planar flow casting nozzle positioned back from the top dead center position with an attached nozzle extension, provides an increased level of casting control and quality. The nozzle extension provides a means of containing the molten pool above the rotating substrate to increase the control of molten metal at the edges of the strip and increase the range of coating thicknesses which may be produced. The level of molten metal in the containment means is regulated to be above the level of melt supplying the casting nozzle which produces a condition of planar drag flow with the casting substrate prior to solidification. 5 figures.

Molten metal reactor and method of forming hydrogen, carbon monoxide and carbon dioxide using the molten alkaline metal reactor

DOEpatents

Bingham, Dennis N.; Klingler, Kerry M.; Turner, Terry D.; Wilding, Bruce M.

2012-11-13

A molten metal reactor for converting a carbon material and steam into a gas comprising hydrogen, carbon monoxide, and carbon dioxide is disclosed. The reactor includes an interior crucible having a portion contained within an exterior crucible. The interior crucible includes an inlet and an outlet; the outlet leads to the exterior crucible and may comprise a diffuser. The exterior crucible may contain a molten alkaline metal compound. Contained between the exterior crucible and the interior crucible is at least one baffle.

Apparatus for efficient sidewall containment of molten metal with horizontal alternating magnetic fields utilizing low reluctance rims

DOEpatents

Praeg, Walter F.

1999-01-01

A method and apparatus for casting sheets of metal from molten metal. The apparatus includes a containment structure having an open side, a horizontal alternating magnetic field generating structure and rollers including low reluctance rim structures. The magnetic field and the rollers help contain the molten metal from leaking out of the containment structure.

Metal atomization spray nozzle

DOEpatents

Huxford, Theodore J.

1993-01-01

A spray nozzle for a magnetohydrodynamic atomization apparatus has a feed passage for molten metal and a pair of spray electrodes mounted in the feed passage. The electrodes, diverging surfaces which define a nozzle throat and diverge at an acute angle from the throat. Current passes through molten metal when fed through the throat which creates the Lorentz force necessary to provide atomization of the molten metal.

Pressurized tundish for controlling a continuous flow of molten metal

DOEpatents

Lewis, Thomas W.; Hamill, Jr., Paul E.; Ozgu, Mustafa R.; Padfield, Ralph C.; Rego, Donovan N.; Brita, Guido P.

1990-01-01

A pressurized tundish for controlling a continous flow of molten metal characterized by having a pair of principal compartments, one being essentially unpressurized and receiving molten metal introduced thereto, and the other being adapted for maintaining a controlled gaseous pressure over the surface of the fluid metal therein, whereby, by controlling the pressure within the pressurized chamber, metal exiting from the tundish is made to flow continually and at a controlled rate.

Molten salt bath circulation design for an electrolytic cell

DOEpatents

Dawless, Robert K.; LaCamera, Alfred F.; Troup, R. Lee; Ray, Siba P.; Hosler, Robert B.

1999-01-01

An electrolytic cell for reduction of a metal oxide to a metal and oxygen has an inert anode and an upwardly angled roof covering the inert mode. The angled roof diverts oxygen bubbles into an upcomer channel, thereby agitating a molten salt bath in the upcomer channel and improving dissolution of a metal oxide in the molten salt bath. The molten salt bath has a lower velocity adjacent the inert anode in order to minimize corrosion by substances in the bath. A particularly preferred cell produces aluminum by electrolysis of alumina in a molten salt bath containing aluminum fluoride and sodium fluoride.

A Winning Cast

NASA Technical Reports Server (NTRS)

2001-01-01

Howmet Research Corporation was the first to commercialize an innovative cast metal technology developed at Auburn University, Auburn, Alabama. With funding assistance from NASA's Marshall Space Flight Center, Auburn University's Solidification Design Center (a NASA Commercial Space Center), developed accurate nickel-based superalloy data for casting molten metals. Through a contract agreement, Howmet used the data to develop computer model predictions of molten metals and molding materials in cast metal manufacturing. Howmet Metal Mold (HMM), part of Howmet Corporation Specialty Products, of Whitehall, Michigan, utilizes metal molds to manufacture net shape castings in various alloys and amorphous metal (metallic glass). By implementing the thermophysical property data from by Auburn researchers, Howmet employs its newly developed computer model predictions to offer customers high-quality, low-cost, products with significantly improved mechanical properties. Components fabricated with this new process replace components originally made from forgings or billet. Compared with products manufactured through traditional casting methods, Howmet's computer-modeled castings come out on top.

Electrolytic purification of metals

DOEpatents

Bowman, Kenneth A.

1980-01-01

A method of electrolytically separating metal from impurities comprises providing the metal and impurities in a molten state in a container having a porous membrane therein, the membrane having a thickness in the range of about 0.01 to 0.1 inch, being capable of containing the molten metal in the container, and being permeable by a molten electrolyte. The metal is electrolytically transferred through the membrane to a cathode in the presence of the electrolyte for purposes of separating or removing impurities from the metal.

Apparatus for efficient sidewall containment of molten metal with horizontal alternating magnetic fields utilizing a ferromagnetic dam

DOEpatents

Praeg, Walter F.

1997-01-01

An apparatus for casting sheets of metal from molten metal. The apparatus includes a containment structure having an open side, a horizontal alternating magnetic field generating structure and a ferromagnetic dam. The magnetic field and the ferromagnetic dam contain the molten metal from leaking out side portions of the open side of the containment structure.

Metal atomization spray nozzle

DOEpatents

Huxford, T.J.

1993-11-16

A spray nozzle for a magnetohydrodynamic atomization apparatus has a feed passage for molten metal and a pair of spray electrodes mounted in the feed passage. The electrodes, diverging surfaces which define a nozzle throat and diverge at an acute angle from the throat. Current passes through molten metal when fed through the throat which creates the Lorentz force necessary to provide atomization of the molten metal. 6 figures.

29 CFR 1926.102 - Eye and face protection.

Code of Federal Regulations, 2013 CFR

2013-07-01

... protection Acetylene—Burning, Acetylene—Cutting, Acetylene—Welding Sparks, harmful rays, molten metal, flying...). Chipping Flying particles 1, 3, 4, 5, 6, 7A, 8A. Electric (arc) welding Sparks, intense rays, molten metal..., molten metal 7, 8, 9 (For severe exposure add 10). Grinding—Light Flying particles 1, 3, 4, 5, 6, 10...

29 CFR 1926.102 - Eye and face protection.

Code of Federal Regulations, 2012 CFR

2012-07-01

... protection Acetylene—Burning, Acetylene—Cutting, Acetylene—Welding Sparks, harmful rays, molten metal, flying...). Chipping Flying particles 1, 3, 4, 5, 6, 7A, 8A. Electric (arc) welding Sparks, intense rays, molten metal..., molten metal 7, 8, 9 (For severe exposure add 10). Grinding—Light Flying particles 1, 3, 4, 5, 6, 10...

29 CFR 1926.102 - Eye and face protection.

Code of Federal Regulations, 2014 CFR

2014-07-01

... protection Acetylene—Burning, Acetylene—Cutting, Acetylene—Welding Sparks, harmful rays, molten metal, flying...). Chipping Flying particles 1, 3, 4, 5, 6, 7A, 8A. Electric (arc) welding Sparks, intense rays, molten metal..., molten metal 7, 8, 9 (For severe exposure add 10). Grinding—Light Flying particles 1, 3, 4, 5, 6, 10...

Plutonium recovery from spent reactor fuel by uranium displacement

DOEpatents

Ackerman, John P.

1992-01-01

A process for separating uranium values and transuranic values from fission products containing rare earth values when the values are contained together in a molten chloride salt electrolyte. A molten chloride salt electrolyte with a first ratio of plutonium chloride to uranium chloride is contacted with both a solid cathode and an anode having values of uranium and fission products including plutonium. A voltage is applied across the anode and cathode electrolytically to transfer uranium and plutonium from the anode to the electrolyte while uranium values in the electrolyte electrolytically deposit as uranium metal on the solid cathode in an amount equal to the uranium and plutonium transferred from the anode causing the electrolyte to have a second ratio of plutonium chloride to uranium chloride. Then the solid cathode with the uranium metal deposited thereon is removed and molten cadmium having uranium dissolved therein is brought into contact with the electrolyte resulting in chemical transfer of plutonium values from the electrolyte to the molten cadmium and transfer of uranium values from the molten cadmium to the electrolyte until the first ratio of plutonium chloride to uranium chloride is reestablished.

Production of Titanium Metal by an Electrochemical Molten Salt Process

NASA Astrophysics Data System (ADS)

Fatollahi-Fard, Farzin

Titanium production is a long and complicated process. What we often consider to be the standard method of primary titanium production (the Kroll process), involves many complex steps both before and after to make a useful product from titanium ore. Thus new methods of titanium production, especially electrochemical processes, which can utilize less-processed feedstocks have the potential to be both cheaper and less energy intensive than current titanium production processes. This project is investigating the use of lower-grade titanium ores with the electrochemical MER process for making titanium via a molten salt process. The experimental work carried out has investigated making the MER process feedstock (titanium oxycarbide) with natural titanium ores--such as rutile and ilmenite--and new ways of using the MER electrochemical reactor to "upgrade" titanium ores or the titanium oxycarbide feedstock. It is feasible to use the existing MER electrochemical reactor to both purify the titanium oxycarbide feedstock and produce titanium metal.

Molten metal feed system controlled with a traveling magnetic field

DOEpatents

Praeg, Walter F.

1991-01-01

A continuous metal casting system in which the feed of molten metal is controlled by means of a linear induction motor capable of producing a magnetic traveling wave in a duct that connects a reservoir of molten metal to a caster. The linear induction motor produces a traveling magnetic wave in the duct in opposition to the pressure exerted by the head of molten metal in the reservoir so that p.sub.c =p.sub.g -p.sub.m where p.sub.c is the desired pressure in the caster, p.sub.g is the gravitational pressure in the duct exerted by the force of the head of molten metal in the reservoir, and p.sub.m is the electromagnetic pressure exerted by the force of the magnetic field traveling wave produced by the linear induction motor. The invention also includes feedback loops to the linear induction motor to control the casting pressure in response to measured characteristics of the metal being cast.

Degassing of molten alloys with the assistance of ultrasonic vibration

DOEpatents

Han, Qingyou; Xu, Hanbing; Meek, Thomas T.

2010-03-23

An apparatus and method are disclosed in which ultrasonic vibration is used to assist the degassing of molten metals or metal alloys thereby reducing gas content in the molten metals or alloys. High-intensity ultrasonic vibration is applied to a radiator that creates cavitation bubbles, induces acoustic streaming in the melt, and breaks up purge gas (e.g., argon or nitrogen) which is intentionally introduced in a small amount into the melt in order to collect the cavitation bubbles and to make the cavitation bubbles survive in the melt. The molten metal or alloy in one version of the invention is an aluminum alloy. The ultrasonic vibrations create cavitation bubbles and break up the large purge gas bubbles into small bubbles and disperse the bubbles in the molten metal or alloy more uniformly, resulting in a fast and clean degassing.

Performance Testing of Molten Regolith Electrolysis with Transfer of Molten Material for the Production of Oxygen and Metals on the Moon

NASA Technical Reports Server (NTRS)

Sibille, Laurent; Sadoway, Donald; Tripathy, Prabhat; Standish, Evan; Sirk, Aislinn; Melendez, Orlando; Stefanescu, Doru

2010-01-01

Previously, we have demonstrated the production of oxygen by electrolysis of molten regolith simulants at temperatures near 1600 C. Using an inert anode and suitable cathode, direct electrolysis (no supporting electrolyte) of the molten silicate is carried out, resulting in the production of molten metallic products at the cathode and oxygen gas at the anode. Initial direct measurements of current efficiency have confirmed that the process offer potential advantages of high oxygen production rates in a smaller footprint facility landed on the moon, with a minimum of consumables brought from Earth. We now report the results of a scale-up effort toward the goal of achieving production rates equivalent to 1 metric ton O2/year, a benchmark established for the support of a lunar base. We previously reported on the electrochemical behavior of the molten electrolyte as dependent on anode material, sweep rate and electrolyte composition in batches of 20-200g and at currents of less than 0.5 A. In this paper, we present the results of experiments performed at currents up to 10 Amperes) and in larger volumes of regolith simulant (500 g - 1 kg) for longer durations of electrolysis. The technical development of critical design components is described, including: inert anodes capable of passing continuous currents of several Amperes, container materials selection, direct gas analysis capability to determine the gas components co-evolving with oxygen. To allow a continuous process, a system has been designed and tested to enable the withdrawal of cathodically-reduced molten metals and spent molten oxide electrolyte. The performance of the withdrawal system is presented and critiqued. The design of the electrolytic cell and the configuration of the furnace were supported by modeling the thermal environment of the system in an effort to realize a balance between external heating and internal joule heating. We will discuss the impact these simulations and experimental findings have on the design of a suitable prototype for lunar applications

Pressurized tundish for controlling a continuous flow of molten metal

DOEpatents

Lewis, T.W.; Hamill, P.E. Jr.; Ozgu, M.R.; Padfield, R.C.; Rego, D.N.; Brita, G.P.

1990-07-24

A pressurized tundish for controlling a continuous flow of molten metal is characterized by having a pair of principal compartments, one being essentially unpressurized and receiving molten metal introduced thereto, and the other being adapted for maintaining a controlled gaseous pressure over the surface of the fluid metal therein, whereby, by controlling the pressure within the pressurized chamber, metal exiting from the tundish is made to flow continually and at a controlled rate. 1 fig.

Spectroscopic studies of transition-metal ions in molten alkali-metal carboxylates

DOE Office of Scientific and Technical Information (OSTI.GOV)

Maroni, V.A.; Maciejewski, M.L.

This paper presents the results of electronic absorption and /sup 13/C-NMR measurements on molten alkali metal formates and acetates and on solutions of selected 3d transition metal ions therein. These studies provide a unique opportunity to explore (1) the highly ordered nature of alkali carboxylates, (2) the ligand field properties of acetate and formate ions, and (3) the coordination chemistry of the 3d transition metals in molten carboxylates. 1 figure, 2 tables.

Supported molten-metal catalysts

DOEpatents

Datta, Ravindra; Singh, Ajeet; Halasz, Istvan; Serban, Manuela

2001-01-01

An entirely new class of catalysts called supported molten-metal catalysts, SMMC, which can replace some of the existing precious metal catalysts used in the production of fuels, commodity chemicals, and fine chemicals, as well as in combating pollution. SMMC are based on supporting ultra-thin films or micro-droplets of the relatively low-melting (<600.degree. C.), inexpensive, and abundant metals and semimetals from groups 1, 12, 13, 14, 15 and 16, of the periodic table, or their alloys and intermetallic compounds, on porous refractory supports, much like supported microcrystallites of the traditional solid metal catalysts. It thus provides orders of magnitude higher surface area than is obtainable in conventional reactors containing molten metals in pool form and also avoids corrosion. These have so far been the chief stumbling blocks in the application of molten metal catalysts.

Thermal Stress Analysis for Ceramics Stalk in the Low Pressure Die Casting Machine

NASA Astrophysics Data System (ADS)

Noda, Nao-Aki; Hendra, Nao-Aki; Takase, Yasushi; Li, Wenbin

Low pressure die casting (LPDC) is defined as a net shape casting technology in which the molten metal is injected at high speeds and pressure into a metallic die. The LPDC process is playing an increasingly important role in the foundry industry as a low-cost and high-efficiency precision forming technique. The LPDC process is that the permanent die and filling systems are placed over the furnace containing the molten alloy. The filling of the cavity is obtained by forcing the molten metal by means of a pressurized gas in order to rise into a ceramic tube, which connects the die to the furnace. The ceramics tube called stalk has high temperature resistance and high corrosion resistance. However, attention should be paid to the thermal stress when the stalk is dipped into the molten aluminum. It is important to develop the design of the stalk to reduce the risk of fracture because of low fracture toughness of ceramics. In this paper, therefore, the finite element method is applied to calculate the thermal stresses when the stalk is dipped into the crucible by varying the dipping speeds and dipping directions. It is found that the thermal stress can be reduced by dipping slowly if the stalk is dipped into the crucible vertically, while the thermal stress can be reduced by dipping fast if it is dipped horizontally.

Computational simulation of weld microstructure and distortion by considering process mechanics

NASA Astrophysics Data System (ADS)

Mochizuki, M.; Mikami, Y.; Okano, S.; Itoh, S.

2009-05-01

Highly precise fabrication of welded materials is in great demand, and so microstructure and distortion controls are essential. Furthermore, consideration of process mechanics is important for intelligent fabrication. In this study, the microstructure and hardness distribution in multi-pass weld metal are evaluated by computational simulations under the conditions of multiple heat cycles and phase transformation. Because conventional CCT diagrams of weld metal are not available even for single-pass weld metal, new diagrams for multi-pass weld metals are created. The weld microstructure and hardness distribution are precisely predicted when using the created CCT diagram for multi-pass weld metal and calculating the weld thermal cycle. Weld distortion is also investigated by using numerical simulation with a thermal elastic-plastic analysis. In conventional evaluations of weld distortion, the average heat input has been used as the dominant parameter; however, it is difficult to consider the effect of molten pool configurations on weld distortion based only on the heat input. Thus, the effect of welding process conditions on weld distortion is studied by considering molten pool configurations, determined by temperature distribution and history.

Multiphysics Modeling for Dimensional Analysis of a Self-Heated Molten Regolith Electrolysis Reactor for Oxygen and Metals Production on the Moon and Mars

NASA Technical Reports Server (NTRS)

Dominguez, Jesus; Sibille, Laurent

2010-01-01

The technology of direct electrolysis of molten lunar regolith to produce oxygen and molten metal alloys has progressed greatly in the last few years. The development of long-lasting inert anodes and cathode designs as well as techniques for the removal of molten products from the reactor has been demonstrated. The containment of chemically aggressive oxide and metal melts is very difficult at the operating temperatures ca. 1600 C. Containing the molten oxides in a regolith shell can solve this technical issue and can be achieved by designing a self-heating reactor in which the electrolytic currents generate enough Joule heat to create a molten bath.

Apparatus for efficient sidewall containment of molten metal with horizontal alternating magnetic fields utilizing a ferromagnetic dam

DOEpatents

Praeg, W.F.

1997-02-11

An apparatus is disclosed for casting sheets of metal from molten metal. The apparatus includes a containment structure having an open side, a horizontal alternating magnetic field generating structure and a ferromagnetic dam. The magnetic field and the ferromagnetic dam contain the molten metal from leaking out side portions of the open side of the containment structure. 25 figs.

30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal. ...

30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2013 CFR

2013-07-01

... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal. ...

30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2014 CFR

2014-07-01

... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal. ...

30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal. ...

30 CFR 57.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2012 CFR

2012-07-01

... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Protective equipment or clothing for welding... equipment or clothing for welding, cutting, or working with molten metal. Protective clothing or equipment and face shields or goggles shall be worn when welding, cutting, or working with molten metal. ...

Method of removal of heavy metal from molten salt in IFR fuel pyroprocessing

DOEpatents

Gay, E.C.

1995-10-03

An electrochemical method is described for separating heavy metal values from a radioactive molten salt including Li halide at temperatures of about 500 C. The method comprises positioning a solid Li--Cd alloy anode in the molten salt containing the heavy metal values, positioning a Cd-containing cathode or a solid cathode positioned above a catch crucible in the molten salt to recover the heavy metal values, establishing a voltage drop between the anode and the cathode to deposit material at the cathode to reduce the concentration of heavy metals in the salt, and controlling the deposition rate at the cathode by controlling the current between the anode and cathode. 3 figs.

Method of removal of heavy metal from molten salt in IFR fuel pyroprocessing

DOEpatents

Gay, Eddie C.

1995-01-01

An electrochemical method of separating heavy metal values from a radioactive molten salt including Li halide at temperatures of about 500.degree. C. The method comprises positioning a solid Li--Cd alloy anode in the molten salt containing the heavy metal values, positioning a Cd-containing cathode or a solid cathode positioned above a catch crucible in the molten salt to recover the heavy metal values, establishing a voltage drop between the anode and the cathode to deposit material at the cathode to reduce the concentration of heavy metals in the salt, and controlling the deposition rate at the cathode by controlling the current between the anode and cathode.

Facile preparation of highly pure KF-ZrF4 molten salt

NASA Astrophysics Data System (ADS)

Zong, Guoqiang; Cui, Zhen-Hua; Zhang, Zhi-Bing; Zhang, Long; Xiao, Ji-Chang

2018-03-01

The preparation of highly pure KF-ZrF4 (FKZr) molten salt, a potential secondary coolant in molten salt reactors, was realized simply by heating a mixture of (NH4)2ZrF6 and KF. X-ray diffraction analysis indicated that the FKZr molten salt was mainly composed of KZrF5 and K2ZrF6. The melting point of the prepared FKZr molten salt was 420-422 °C under these conditions. The contents of all metal impurities were lower than 20 ppm, and the content of oxygen was lower than 400 ppm. This one-step protocol avoids the need for a tedious procedure to prepare ZrF4 and for an additional purification process to remove oxide impurities, and is therefore a convenient, efficient and economic preparation method for high-purity FKZr molten salt.

Molten salt bath circulation design for an electrolytic cell

DOEpatents

Dawless, R.K.; LaCamera, A.F.; Troup, R.L.; Ray, S.P.; Hosler, R.B.

1999-08-17

An electrolytic cell for reduction of a metal oxide to a metal and oxygen has an inert anode and an upwardly angled roof covering the inert mode. The angled roof diverts oxygen bubbles into an upcomer channel, thereby agitating a molten salt bath in the upcomer channel and improving dissolution of a metal oxide in the molten salt bath. The molten salt bath has a lower velocity adjacent the inert anode in order to minimize corrosion by substances in the bath. A particularly preferred cell produces aluminum by electrolysis of alumina in a molten salt bath containing aluminum fluoride and sodium fluoride. 4 figs.

Convection effects on Skylab experiments M551, M552, and M553, phase C report. [metal melting, exothermic brazing, and sphere forming under weightless conditions

NASA Technical Reports Server (NTRS)

Bourgeois, S. V.

1973-01-01

This report described an analysis of Skylab Experiments M551 (Metals Melting), M552 (Exothermic Brazing), and M553 (Sphere Forming). The primary objective is the study of convection in the molten metals and their attendant solidification theory. Particular attention is given to clarifying the effects of reduced gravity on molten metal flow and solidification. Based on an analysis of physical forces and solidification theory expected for ground-based and Skylab processing, low-g variations were predicted for each experiment. A comparison was then made with the Skylab results available to date. Both metallurgical analyses of other investigators and movies of ground-based and Skylab samples were utilized. Several low-g variations in Skylab processed materials were successfully predicted based on expected variations in physical forces and fluid convection. The same analysis also successfully predicted several features in the Skylab-processed materials which were identical to terrestrially-processed materials. These results are summarized in the conclusion section for each experiment.

Production of oxygen from lunar soil by molten salt electrolysis

NASA Technical Reports Server (NTRS)

Keller, Rudolf

1989-01-01

A simple approach to utilizing lunar resources proposes to dissolve lunar soil, without or with little beneficiation, in a suitable molten salt and to electrolyze the oxides to oxygen and a metal byproduct. The envisioned process and the required technological advances are discussed. Promising electrolysis conditions have been identified in a recent experimental program to manufacture silicon and aluminum from anorthite.

Joule-Heated Molten Regolith Electrolysis Reactor Concepts for Oxygen and Metals Production on the Moon and Mars

NASA Technical Reports Server (NTRS)

Sibille, Laurent; Dominguez, Jesus A.

2012-01-01

The technology of direct electrolysis of molten lunar regolith to produce oxygen and molten metal alloys has progressed greatly in the last few years. The development of long-lasting inert anodes and cathode designs as well as techniques for the removal of molten products from the reactor has been demonstrated. The containment of chemically aggressive oxide and metal melts is very difficult at the operating temperatures ca. 1600 C. Containing the molten oxides in a regolith shell can solve this technical issue and can be achieved by designing a Joule-heated (sometimes called 'self-heating') reactor in which the electrolytic currents generate enough Joule heat to create a molten bath. Solutions obtained by multiphysics modeling allow the identification of the critical dimensions of concept reactors.

Behavior and structure of metal vapor arc plasma between molten electrodes

NASA Astrophysics Data System (ADS)

Zanner, F. J.; Williamson, R. L.; Hareland, W. A.; Bertram, L. A.

A metal vapor arc is utilized in the industrially important vacuum arc remelting (VAR) process to produce materials by melting and resolidification which have improved structure and chemical homogeneity. Homogeneity is dependent on achieving quasi-steady conditions in the plasma because of its thermal and MHD coupling with the molten pool atop the ingot. Optimal operating conditions of low pressure (approx. = 0.01 torr) and short electrode gap (less than 15 mm) produce a diffuse arc and cathode spot behavior similar to that observed for the vacuum breaker arc. Under these conditions the arc provides a quasi-steady heat source that is considered to be the bench mark arc of the VAR process. Previous work has shown that deviation from the bench mark arc behavior can occur under production conditions, and is caused by electrode irregularities and liberation of gases such as CO from the molten pool. This study is an effort to characterize these behavioral deviations and discover operational conditions which stabilize the bench mark arc.

Process Demonstration For Lunar In Situ Resource Utilization-Molten Oxide Electrolysis (MSFC Independent Research and Development Project No. 5-81)

NASA Technical Reports Server (NTRS)

Curreri, P. A.; Ethridge, E. C.; Hudson, S. B.; Miller, T. Y.; Grugel, R. N.; Sen, S.; Sadoway, D. R.

2006-01-01

The purpose of this Focus Area Independent Research and Development project was to conduct, at Marshall Space Flight Center, an experimental demonstration of the processing of simulated lunar resources by the molten oxide electrolysis process to produce oxygen and metal. In essence, the vision was to develop two key technologies, the first to produce materials (oxygen, metals, and silicon) from lunar resources and the second to produce energy by photocell production on the Moon using these materials. Together, these two technologies have the potential to greatly reduce the costs and risks of NASA s human exploration program. Further, it is believed that these technologies are the key first step toward harvesting abundant materials and energy independent of Earth s resources.

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space

NASA Technical Reports Server (NTRS)

Fragomeni, James M.; Nunes, Arthur C., Jr.

1998-01-01

The safety issue has been raised with regards to potential molten metal detachments from the weld pool and cold filler wire during electron beam welding in space. This investigation was undertaken to evaluate if molten metal could detach and come in contact with astronauts and burn through the fabric of the astronauts' Extravehicular Mobility Unit (EMU) during electron beam welding in space. Molten metal detachments from either the weld/cut substrate or weld wire could present harm to a astronaut if the detachment was to burn through the fabric of the EMU. Theoretical models were developed to predict the possibility and size of the molten metal detachment hazards during the electron beam welding exercises at Low Earth Orbit (LEO). The primary molten metal detachment concerns were those cases of molten metal separation from the metal surface due to metal cutting, weld pool splashing, entrainment and release of molten metal due to filler wire snap-out from the weld puddle, and molten metal accumulation and release from the end of the weld wire. Some possible ways of obtaining molten metal drop detachments would include an impulse force, or bump, to the weld sample, cut surface, or filler wire. Theoretical models were developed for these detachment concerns from principles of impact and kinetic energies, surface tension, drop geometry, surface energies, and particle dynamics. The surface tension represents the force opposing the liquid metal drop from detaching whereas the weight of the liquid metal droplet represents a force that is tending to detach the molten metal drop. Theoretical calculations have indicated that only a small amount of energy is required to detach a liquid metal drop; however, much of the energy of an impact is absorbed in the sample or weld plate before it reaches the metal drop on the cut edge or surface. The tendency for detachment is directly proportional to the weld pool radius and metal density and inversely proportional to the surface tension of the liquid metal. For a detachment the initial kinetic energy of the weld pool with respect to the plate has to exceed the energy to form the extra surface required for the detachment of the pool. The difficulty is in transferring the energy from the point of impact through the plate and sample to the cut edge. It is likely that not all of the kinetic energy is available for detaching the pool; some may be sequestered in weld pool oscillations. The coefficient of restitution for the collision will be lower than one if irreversible deformation, for example plastic flow deformation, takes place during the collision. Thus determining the amount of energy from an impact that actually reaches the molten metal droplet is critical. Various molten metal detachment scenarios were tested experimentally in an enclosed vacuum chamber using the Ukrainian Universal Hand Tool, an electron beam welder designed for space welding. The experimental testing was performed in a 4 ft. X 4 ft. vacuum chamber at Marshall Space Flight Center, evacuated to vacuum levels of at least 50 microTorr, and also some welding garment material was utilized to observe the effect of the molten metal detachments on the material. A "carillon" apparatus consisting of four pendulum hammer strikers, each weighing approximately 3.65 lbs, raised to predetermined specific heights was used to apply an impact force to the weld sample/plate during electron beam welding and cutting exercises. The strikers were released by switching on an electric motor to rotate a pin holding wires retaining the strikers at desired heights. The specimens were suspended so as to be free to respond to the blows with a sudden velocity increment. The specimens were mounted on a hinged plate for minimizing effective mass with the option to fasten it down so as to raise its effective mass closer to that anticipated for an actual space welding scenario. Measurements were made of the impact energy and the horizontal fling distances of the detached metal drops. It was not particularly easy to generate the detachments fo

Metallurgical technologies, energy conversion, and magnetohydrodynamic flows

NASA Astrophysics Data System (ADS)

Branover, Herman; Unger, Yeshajahu

The present volume discusses metallurgical applications of MHD, R&D on MHD devices employing liquid working medium for process applications, electromagnetic (EM) modulation of molten metal flow, EM pump performance of superconducting MHD devices, induction EM alkali-metal pumps, a physical model for EM-driven flow in channel-induction furnaces, grain refinement in Al alloys via EM vibrational method, dendrite growth of solidifying metal in dc magnetic field, MHD for mass and heat transfer in single-crystal melt growth, inverse EM shaping, and liquid-metal MHD development in Israel. Also discussed are the embrittlement of steel by lead, an open cycle MHD disk generator, the acceleration of gas-liquid piston flows for molten-metal MHD generators, MHD flow around a cylinder, new MHD drag coefficients, liquid-metal MHD two-phase flow, and two-phase liquid gas mixers for MHD energy conversion. (No individual items are abstracted in this volume)

Thin sheet casting with electromagnetic pressurization

DOEpatents

Walk, Steven R.; Slepian, R. Michael; Nathenson, Richard D.; Williams, Robert S.

1991-01-01

An apparatus, method and system for the casting of thin strips or strips of metal upon a moving chill block that includes an electromagnet located so that molten metal poured from a reservoir onto the chill block passes into the magnetic field produced by the electromagnet. The electromagnet produces a force on the molten metal on said chill block in the direction toward said chill block in order to enhance thermal contact between the molten metal and the chill block.

Influence of rotational speed of centrifugal casting process on appearance, microstructure, and sliding wear behaviour of Al-2Si cast alloy

NASA Astrophysics Data System (ADS)

Mukunda, P. G.; Shailesh, Rao A.; Rao, Shrikantha S.

2010-02-01

Although the manner in which the molten metal flows plays a major role in the formation of the uniform cylinder in centrifugal casting, not much information is available on this topic. The flow in the molten metal differs at various rotational speeds, which in turn affects the final casting. In this paper, the influence of the flow of molten metal of hyper eutectic Al-2Si alloys at various rotational speeds is discussed. At an optimum speed of 800 rpm, a uniform cylinder was formed. For the rotational speeds below and above these speeds, an irregular shaped casting was formed, which is mainly due to the influence of melt. Primary á-Al particles were formed in the tube periphery at low rotational speed, and their sizes and shapes were altered with changes in rotational speeds. The wear test for the inner surface of the casting showed better wear properties for the casting prepared at the optimum speed of rotation.

Production of chlorine from chloride salts

DOEpatents

Rohrmann, Charles A.

1981-01-01

A process for converting chloride salts and sulfuric acid to sulfate salts and elemental chlorine is disclosed. A chloride salt and sulfuric acid are combined in a furnace where they react to produce a sulfate salt and hydrogen chloride. Hydrogen chloride from the furnace contacts a molten salt mixture containing an oxygen compound of vanadium, an alkali metal sulfate and an alkali metal pyrosulfate to recover elemental chlorine. In the absence of an oxygen-bearing gas during the contacting, the vanadium is reduced, but is regenerated to its active higher valence state by separately contacting the molten salt mixture with an oxygen-bearing gas.

Oxidation of hydrogen halides to elemental halogens

DOEpatents

Rohrmann, Charles A.; Fullam, Harold T.

1985-01-01

A process for oxidizing hydrogen halides having substantially no sulfur impurities by means of a catalytically active molten salt is disclosed. A mixture of the subject hydrogen halide and an oxygen bearing gas is contacted with a molten salt containing an oxidizing catalyst and alkali metal normal sulfates and pyrosulfates to produce an effluent gas stream rich in the elemental halogen and substantially free of sulfur oxide gases.

Carbothermal Processing of Lunar Regolith Using Methane

NASA Technical Reports Server (NTRS)

Balasubramaniam, R.; Hegde, U.; Gokoglu, S.

2009-01-01

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. Among various candidate processes, the modeling of oxygen production by hydrogen reduction, molten salt electrolysis, and carbothermal processing are presently being pursued. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source such as a laser beam or a concentrated solar heat flux, so that a small zone of molten regolith is established. The molten zone is surrounded by solid regolith particles that are poor conductors of heat. A continuous flow of methane is maintained over the molten regolith zone. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. Oxygen is produced subsequently by (catalytically) processing the carbon monoxide downstream. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide.

Carbothermal Processing of Lunar Regolith Using Methane

NASA Technical Reports Server (NTRS)

Balasubramaniam, R.; Hegde, U.; Gokoglu, S.

2008-01-01

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. Among various candidate processes, the modeling of oxygen production by hydrogen reduction, molten salt electrolysis, and carbothermal processing are presently being pursued. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source such as a laser beam or a concentrated solar heat flux, so that a small zone of molten regolith is established. The molten zone is surrounded by solid regolith particles that are poor conductors of heat. A continuous flow of methane is maintained over the molten regolith zone. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. Oxygen is produced subsequently by (catalytically) processing the carbon monoxide downstream. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide.

Plutonium recovery from spent reactor fuel by uranium displacement

DOEpatents

Ackerman, J.P.

1992-03-17

A process is described for separating uranium values and transuranic values from fission products containing rare earth values when the values are contained together in a molten chloride salt electrolyte. A molten chloride salt electrolyte with a first ratio of plutonium chloride to uranium chloride is contacted with both a solid cathode and an anode having values of uranium and fission products including plutonium. A voltage is applied across the anode and cathode electrolytically to transfer uranium and plutonium from the anode to the electrolyte while uranium values in the electrolyte electrolytically deposit as uranium metal on the solid cathode in an amount equal to the uranium and plutonium transferred from the anode causing the electrolyte to have a second ratio of plutonium chloride to uranium chloride. Then the solid cathode with the uranium metal deposited thereon is removed and molten cadmium having uranium dissolved therein is brought into contact with the electrolyte resulting in chemical transfer of plutonium values from the electrolyte to the molten cadmium and transfer of uranium values from the molten cadmium to the electrolyte until the first ratio of plutonium chloride to uranium chloride is reestablished.

Uranium dioxide electrolysis

DOEpatents

Willit, James L [Batavia, IL; Ackerman, John P [Prescott, AZ; Williamson, Mark A [Naperville, IL

2009-12-29

This is a single stage process for treating spent nuclear fuel from light water reactors. The spent nuclear fuel, uranium oxide, UO.sub.2, is added to a solution of UCl.sub.4 dissolved in molten LiCl. A carbon anode and a metallic cathode is positioned in the molten salt bath. A power source is connected to the electrodes and a voltage greater than or equal to 1.3 volts is applied to the bath. At the anode, the carbon is oxidized to form carbon dioxide and uranium chloride. At the cathode, uranium is electroplated. The uranium chloride at the cathode reacts with more uranium oxide to continue the reaction. The process may also be used with other transuranic oxides and rare earth metal oxides.

Observations of impact-induced molten metal-silicate partitioning

NASA Technical Reports Server (NTRS)

Rowan, Linda R.; Ahrens, Thomas J.

1994-01-01

Observations of molten mid-ocean ridge basalt (MORB)-molybdenum (Mo) interactions produced by shock experiments provide insight into impact and differentiation processes involving metal-silicate partitioning. Analysis of fragments recovered from experiments (achieving MORB liquid shock pressures from 0.8 to 6 GPa) revealed significant changes in the composition of the MORB and Mo due to reaction of the silicate and metal liquids on a short time scale (less than 13 s). The FeO concentration of the shocked liquid decreases systematically with increasing pressure. In fact, the most highly shocked liquid (6 GPa) contains only 0.1 wt% FeO compared to an initial concentration of 9 wt% in the MORB. We infer from the presence of micrometer-sized Fe-, Si- and Mo-rich metallic spheres in the shocked glass that the Fe and Si oxides in the MORB were reduced in an estimated oxygen fugacity of 10(exp -17) bar and subsequently alloyed with the Mo. The in-situ reduction of FeO in the shocked molten basalt implies that shock-induced reduction of impact melt should be considered a viable mechanism for the formation of metallic phases. Similar metallic phases may form during impact accretion of planets and in impacted material found on the lunar surface and near terrestrial impact craters. In particular, the minute, isolated Fe particles found in lunar soils may have formed by such a process. Furthermore, the metallic spheres within the shocked glass have a globular texture similar to the textures of metallic spheroids from lunar samples and the estimated, slow cooling rate of less than or equal to 140 C/s for our spheres is consistent with the interpretation that the lunar spheroids formed by slow cooling within a melted target.

Effects of Cations on Corrosion of Inconel 625 in Molten Chloride Salts

NASA Astrophysics Data System (ADS)

Zhu, Ming; Ma, Hongfang; Wang, Mingjing; Wang, Zhihua; Sharif, Adel

2016-04-01

Hot corrosion of Inconel 625 in sodium chloride, potassium chloride, magnesium chloride, calcium chloride and their mixtures with different compositions is conducted at 900°C to investigate the effects of cations in chloride salts on corrosion behavior of the alloy. XRD, SEM/EDS were used to analyze the compositions, phases, and morphologies of the corrosion products. The results showed that Inconel 625 suffers more severe corrosion in alkaline earth metal chloride molten salts than alkaline metal chloride molten salts. For corrosion in mixture salts, the corrosion rate increased with increasing alkaline earth metal chloride salt content in the mixture. Cations in the chloride molten salts mainly affect the thermal and chemical properties of the salts such as vapor pressure and hydroscopicities, which can affect the basicity of the molten salt. Corrosion of Inconel 625 in alkaline earth metal chloride salts is accelerated with increasing basicity.

Height Control and Deposition Measurement for the Electron Beam Free Form Fabrication (EBF3) Process

NASA Technical Reports Server (NTRS)

Hafley, Robert A. (Inventor); Seufzer, William J. (Inventor)

2017-01-01

A method of controlling a height of an electron beam gun and wire feeder during an electron freeform fabrication process includes utilizing a camera to generate an image of the molten pool of material. The image generated by the camera is utilized to determine a measured height of the electron beam gun relative to the surface of the molten pool. The method further includes ensuring that the measured height is within the range of acceptable heights of the electron beam gun relative to the surface of the molten pool. The present invention also provides for measuring a height of a solid metal deposit formed upon cooling of a molten pool. The height of a single point can be measured, or a plurality of points can be measured to provide 2D or 3D surface height measurements.

New Engineering Solutions in Creation of Mini-BOF for Metallic Waste Recycling

NASA Astrophysics Data System (ADS)

Eronko, S. P.; Gorbatyuk, S. M.; Oshovskaya, E. V.; Starodubtsev, B. I.

2017-12-01

New engineering solutions used in design of the mini melting unit capable of recycling industrial and domestic metallic waste with high content of harmful impurities are provided. High efficiency of the process technology implemented with its use is achieved due to the possibility of the heat and mass transfer intensification in the molten metal bath, controlled charge into it of large amounts of reagents in lumps and in fines, and cut-off of remaining process slag during metal tapping into the teeming ladle.

From Oxygen Generation to Metals Production: In Situ Resource Utilization by Molten Oxide Electrolysis

NASA Technical Reports Server (NTRS)

Khetpal, Deepak; Ducret, Andrew C.; Sadoway, Donald R.

2003-01-01

For the exploration of other bodies in the solar system, electrochemical processing is arguably the most versatile technology for conversion of local resources into usable commodities: by electrolysis one can, in principle, produce (1) breathable oxygen, (2) silicon for the fabrication of solar cells, (3) various reactive metals for use as electrodes in advanced storage batteries, and (4) structural metals such as steel and aluminum. Even so, to date there has been no sustained effort to develop such processes, in part due to the inadequacy of the database. The objective here is to identify chemistries capable of sustaining molten oxide electrolysis in the cited applications and to examine the behavior of laboratory-scale cells designed to generate oxygen and to produce metal. The basic research includes the study of the underlying high-temperature physical chemistry of oxide melts representative of lunar regolith and of Martian soil. To move beyond empirical approaches to process development, the thermodynamic and transport properties of oxide melts are being studied to help set the limits of composition and temperature for the processing trials conducted in laboratory-scale electrolysis cells. The goal of this investigation is to deliver a working prototype cell that can use lunar regolith and Martian soil to produce breathable oxygen along with metal by-product. Additionally, the process can be generalized to permit adaptation to accommodate different feedstock chemistries, such as those that will be encountered on other bodies in the solar system. The expected results of this research include: (1) the identification of appropriate electrolyte chemistries; (2) the selection of candidate anode and cathode materials compatible with electrolytes named above; and (3) performance data from a laboratory-scale cell producing oxygen and metal. On the strength of these results it should be possible to assess the technical viability of molten oxide electrolysis for in situ resource utilization on the Moon and Mars. In parallel, there may be commercial applications here on earth, such as new green technologies for metals extraction and for treatment of hazardous waste, e.g., fixing heavy metals.

Reprocessing of LiH in Molten Chlorides

NASA Astrophysics Data System (ADS)

Masset, Patrick J.; Gabriel, Armand; Poignet, Jean-Claude

2008-06-01

LiH was used as inactive material to stimulate the reprocessing of lithium tritiate in molten chlorides. The electrochemical properties (diffusion coefficients, apparent standard potentials) were measured by means of transient electrochemical techniques (cyclic voltammetry and chronopotentiometry). At 425 ºC the diffusion coefficient and the apparent standard potential were 2.5 · 10-5 cm2 s-1 and -1.8 V vs. Ag/AgCl, respectively. For the process design the LiH solubility was measured by means of DTA to optimize the LiH concentration in the molten phase. In addition electrolysis tests were carried out at 460 ºC with current densities up to 1 A cm-2 over 24 h. These results show that LiH may be reprocessed in molten chlorides consisting in the production of hydrogen gas at the anode and molten metallic lithium at the cathode.

30 CFR 57.16013 - Working with molten metal.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Working with molten metal. 57.16013 Section 57.16013 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND HEALTH SAFETY AND HEALTH STANDARDS-UNDERGROUND METAL AND NONMETAL MINES Materials...

30 CFR 57.16013 - Working with molten metal.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Working with molten metal. 57.16013 Section 57.16013 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND HEALTH SAFETY AND HEALTH STANDARDS-UNDERGROUND METAL AND NONMETAL MINES Materials...

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space

NASA Technical Reports Server (NTRS)

Fragomeni, James M.; Nunes, Arthur C., Jr.

1998-01-01

The safety issue has been raised with regards to potential molten metal detachments from the weld pool and cold filler wire during electron beam welding in space. This investigation was undertaken to evaluate if molten metal could detach and come in contact with astronauts and burn through the fabric of the astronauts' Extravehicular Mobility Unit (EMU) during electron beam welding in space. Molten metal detachments from either the weld/cut substrate or weld wire could present harm to a astronaut if the detachment was to burn through the fabric of the EMU. Theoretical models were developed to predict the possibility and size of the molten metal detachment hazards during the electron beam welding exercises at Low Earth Orbit (LEO). The primary molten metal detachment concerns were those cases of molten metal separation from the metal surface due to metal cutting, weld pool splashing, entrainment and release of molten metal due to filler wire snap-out from the weld puddle, and molten metal accumulation and release from the end of the weld wire. Some possible ways of obtaining molten metal drop detachments would include an impulse force, or bump, to the weld sample, cut surface, or filler wire. Theoretical models were developed for these detachment concerns from principles of impact and kinetic energies, surface tension, drop geometry, surface energies, and particle dynamics. The surface tension represents the force opposing the liquid metal drop from detaching whereas the weight of the liquid metal droplet represents a force that is tending to detach the molten metal drop. Theoretical calculations have indicated that only a small amount of energy is required to detach a liquid metal drop; however, much of the energy of an impact is absorbed in the sample or weld plate before it reaches the metal drop on the cut edge or surface. The tendency for detachment is directly proportional to the weld pool radius and metal density and inversely proportional to the surface tension of the liquid metal. For a detachment the initial kinetic energy of the weld pool with respect to the plate has to exceed the energy to form the extra surface required for the detachment of the pool. The difficulty is in transferring the energy from the point of impact through the plate and sample to the cut edge. It is likely that not all of the kinetic energy is available for detaching the pool; some may be sequestered in weld pool oscillations. The coefficient of restitution for the collision will be lower than one if irreversible deformation, for example plastic flow deformation, takes place during the collision. Thus determining the amount of energy from an impact that actually reaches the molten metal droplet is critical. Various molten metal detachment scenarios were tested experimentally in an enclosed vacuum chamber using the Ukrainian Universal Hand Tool, an electron beam welder designed for space welding. The experimental testing was performed in a 4 ft. X 4 ft. vacuum chamber at Marshall Space Flight Center, evacuated to vacuum levels of at least 50 microTorr, and also some welding garment material was utilized to observe the effect of the molten metal detachments on the material. A "carillon" apparatus consisting of four pendulum hammer strikers, each weighing approximately 3.65 lbs, raised to predetermined specific heights was used to apply an impact force to the weld sample/plate during electron beam welding and cutting exercises. The strikers were released by switching on an electric motor to rotate a pin holding wires retaining the strikers at desired heights. The specimens were suspended so as to be free to respond to the blows with a sudden velocity increment. The specimens were mounted on a hinged plate for minimizing effective mass with the option to fasten it down so as to raise its effective mass closer to that anticipated for an actual space welding scenario. Measurements were made of the impact energy and the horizontal fling distances of the detached metal drops. It was not particularly easy to generate the detachments for this experiment. This document presents the details of the theoretical modeling effort and a summary of the experimental effort to measure molten metal drop detachments from terrestrial electron beam welding in the enclosed vacuum chamber. The results of the experimental effort have shown that molten metal detachments can occur from the sample/weld plate only if a sufficiently large impact force is applied to the weld plate. A "weld pool detachment parameter" was determined to indicate whether detachment would occur. Detachment can be either full or partial (dripping), Partial detachment means that the weld pool detached from one side of the liquid-solid boundary so as to leave a hole at the puddle site but remained attached over part of the liquid-solid boundary and dripped down the plate with no fully detached material detected. Full detachment, however, does not necessarily mean that the whole pool fully detached; in some cases only a smaller portion of the pool detached, the remainder dripping down the plate. The weld pool detachment parameter according to theory and according to the empirical data allows a determination of whether full detachments might occur. Theoretical calculations indicated titanium alloy would be the most difficult from which to detach molten metal droplets followed by stainless steel and then by aluminum. The experimental results were for the most part consistent with the theoretical analysis and predictions. The above theory is applicable to other situations as desired for assessing the potential for molten metal detachments.

LEVELING METAL COATINGS

DOEpatents

Gage, H.A.

1959-02-10

A method is described for applying metallic coatings to a cylinder of uranium. An aluminum-silicon coat is applied by a process consisting of first cleaning the article by immersion for 5 minutes in 50% nitric acid at 65 C. The article then is dipped through a flux, prepared by adding 10% sodium fluoride to 90% of a flux comprising 53% potassium chloride, 42% lithium chloride, and 5% sodium chloride at 560 for 2 minutes and then directly into a molten metal bath comprising 99% aluminun and 12% silicon at 620 C for 3 minutes. While the coating is yet molten the article is transferred to a pair of steel rollers and rolled until the coating solidifies. By varying the composition of the flux other metals such as zinc, lead or the like may be coated on uranium in a similar manner.

Method and apparatus for jetting, manufacturing and attaching uniform solder balls

DOEpatents

Yost, F.G.; Frear, D.R.; Schmale, D.T.

1999-01-05

An apparatus and process are disclosed for jetting molten solder in the form of balls directly onto all the metallized interconnects lands for a ball grid array package in one step with no solder paste required. Molten solder is jetted out of a grid of holes using a piston attached to a piezoelectric crystal. When voltage is applied to the crystal it expands forcing the piston to extrude a desired volume of solder through holes in the aperture plate. When the voltage is decreased the piston reverses motion creating an instability in the molten solder at the aperture plate surface and thereby forming spherical solder balls that fall onto a metallized substrate. The molten solder balls land on the substrate and form a metallurgical bond with the metallized lands. The size of the solder balls is determined by a combination of the size of the holes in the aperture plate, the duration of the piston pulse, and the displacement of the piston. The layout of the balls is dictated by the location of the hooks in the grid. Changes in ball size and layout can be easily accomplished by changing the grid plate. This invention also allows simple preparation of uniform balls for subsequent supply to BGA users. 7 figs.

Method and apparatus for jetting, manufacturing and attaching uniform solder balls

DOEpatents

Yost, Frederick G.; Frear, Darrel R.; Schmale, David T.

1999-01-01

An apparatus and process for jetting molten solder in the form of balls directly onto all the metallized interconnects lands for a ball grid array package in one step with no solder paste required. Molten solder is jetted out of a grid of holes using a piston attached to a piezoelectric crystal. When voltage is applied to the crystal it expands forcing the piston to extrude a desired volume of solder through holes in the aperture plate. When the voltage is decreased the piston reverses motion creating an instability in the molten solder at the aperture plate surface and thereby forming spherical solder balls that fall onto a metallized substrate. The molten solder balls land on the substrate and form a metallurgical bond with the metallized lands. The size of the solder balls is determined by a combination of the size of the holes in the aperture plate, the duration of the piston pulse, and the displacement of the piston. The layout of the balls is dictated by the location of the hooks in the grid. Changes in ball size and layout can be easily accomplished by changing the grid plate. This invention also allows simple preparation of uniform balls for subsequent supply to BGA users.

Systems and Methods for Fabricating Structures Including Metallic Glass-Based Materials Using Low Pressure Casting

NASA Technical Reports Server (NTRS)

Hofmann, Douglas C. (Inventor); Kennett, Andrew (Inventor)

2018-01-01

Systems and methods to fabricate objects including metallic glass-based materials using low-pressure casting techniques are described. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: introducing molten alloy into a mold cavity defined by a mold using a low enough pressure such that the molten alloy does not conform to features of the mold cavity that are smaller than 100 microns; and cooling the molten alloy such that it solidifies, the solid including a metallic glass-based material.

Wick-and-pool electrodes for electrochemical cell

DOEpatents

Roche, Michael F.; Faist, Suzan M.; Eberhart, James G.; Ross, Laurids E.

1977-01-01

An electrode system includes a reservoir of liquid-metal reactant, and a wick extending from a submersed location within the reservoir into the molten electrolyte of an electrochemical cell structure. The wick is flooded with the liquid metal and thereby serves as one electrode within the cell. This electrode system has application in high-temperature batteries employing molten alkali metals or their alloys as active material within an electrode submersed within a molten salt electrolyte. It also can be used in electrochemical cells where the purification, separation or electrowinning of liquid metals is accomplished.

Wick-and-pool electrodes for electrochemical cell

DOEpatents

Roche, Michael F.; Faist, Suzan M.; Eberhart, James G.; Ross, Laurids E.

1980-01-01

An electrode system includes a reservoir of liquid-metal reactant, and a wick extending from a submersed location within the reservoir into the molten electrolyte of an electrochemical cell structure. The wick is flooded with the liquid metal and thereby serves as one electrode within the cell. This electrode system has application in high-temperature batteries employing molten alkali metals or their alloys as active material within an electrode submersed within a molten salt electrolyte. It also can be used in electrochemical cells where the purification, separation or electrowinning of liquid metals is accomplished.

30 CFR 56.16013 - Working with molten metal.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Working with molten metal. 56.16013 Section 56.16013 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND HEALTH SAFETY AND HEALTH STANDARDS-SURFACE METAL AND NONMETAL MINES Materials Storage...

30 CFR 56.16013 - Working with molten metal.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Working with molten metal. 56.16013 Section 56.16013 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND HEALTH SAFETY AND HEALTH STANDARDS-SURFACE METAL AND NONMETAL MINES Materials Storage...

Fabrication of cast particle-reinforced metals via pressure infiltration

NASA Technical Reports Server (NTRS)

Klier, E. M.; Mortensen, A.; Cornie, J. A.; Flemings, M. C.

1991-01-01

A new casting process for fabrication of particle-reinforced metals is presented whereby a composite of particulate reinforcing phase in metal is first produced by pressure infiltration. This composite is then diluted in additional molten metal to obtain the desired reinforcement volume fraction and metal composition. This process produces a pore-free as-cast particulate metal-matrix composite. This process is demonstrated for fabrication of magnesium-matrix composites containing SiC reinforcements of average diameter 30, 10 and 3 microns. It is compared with the compocasting process, which was investigated as well for similar SiC particles in Mg-10 wt pct Al, and resulted in unacceptable levels of porosity in the as-cast composite.

Joule-Heated Molten Regolith Electrolysis Reactor Concepts for Oxygen and Metals Production on the Moon and Mars

NASA Technical Reports Server (NTRS)

Sibille, Laurent; Dominques, Jesus A.

2012-01-01

The maturation of Molten Regolith Electrolysis (MRE) as a viable technology for oxygen and metals production on explored planets relies on the realization of the self-heating mode for the reactor. Joule heat generated during regolith electrolysis creates thermal energy that should be able to maintain the molten phase (similar to electrolytic Hall-Heroult process for aluminum production). Self-heating via Joule heating offers many advantages: (1) The regolith itself is the crucible material, it protects the vessel walls (2) Simplifies the engineering of the reactor (3) Reduces power consumption (no external heating) (4) Extends the longevity of the reactor. Predictive modeling is a tool chosen to perform dimensional analysis of a self-heating reactor: (1) Multiphysics modeling (COMSOL) was selected for Joule heat generation and heat transfer (2) Objective is to identify critical dimensions for first reactor prototype.

Progress on Numerical Modeling of the Dispersion of Ceramic Nanoparticles During Ultrasonic Processing and Solidification of Al-Based Nanocomposites

NASA Astrophysics Data System (ADS)

Zhang, Daojie; Nastac, Laurentiu

2016-12-01

In present study, 6061- and A356-based nano-composites are fabricated by using the ultrasonic stirring technology (UST) in a coreless induction furnace. SiC nanoparticles are used as the reinforcement. Nanoparticles are added into the molten metal and then dispersed by ultrasonic cavitation and acoustic streaming assisted by electromagnetic stirring. The applied UST parameters in the current experiments are used to validate a recently developed magneto-hydro-dynamics (MHD) model, which is capable of modeling the cavitation and nanoparticle dispersion during UST processing. The MHD model accounts for turbulent fluid flow, heat transfer and solidification, and electromagnetic field, as well as the complex interaction between the nanoparticles and both the molten and solidified alloys by using ANSYS Maxwell and ANSYS Fluent. Molecular dynamics (MD) simulations are conducted to analyze the complex interactions between the nanoparticle and the liquid/solid interface. The current modeling results demonstrate that a strong flow can disperse the nanoparticles relatively well during molten metal and solidification processes. MD simulation results prove that ultrafine particles (10 nm) will be engulfed by the solidification front instead of being pushed, which is beneficial for nano-dispersion.

Method for determining molten metal pool level in twin-belt continuous casting machines

DOEpatents

Kaiser, Timothy D.; Daniel, Sabah S.; Dykes, Charles D.

1989-03-21

A method for determining level of molten metal in the input of a continuous metal casting machine having at least one endless, flexible, revolving casting belt with a surface which engages the molten metal to be cast and a reverse, cooled surface along which is directed high velocity liquid coolant includes the steps of predetermining the desired range of positions of the molten metal pool and positioning at least seven heat-sensing transducers in bearing contact with the moving reverse belt surface and spaced in upstream-downstream relationship relative to belt travel spanning the desired pool levels. A predetermined temperature threshold is set, somewhat above coolant temperature and the output signals of the transducer sensors are scanned regarding their output signals indicative of temperatures of the moving reverse belt surface. Position of the molten pool is determined using temperature interpolation between any successive pair of upstream-downstream spaced sensors, which follows confirmation that two succeeding downstream sensors are at temperature levels exceeding threshold temperature. The method accordingly provides high resolution for determining pool position, and verifies the determined position by utilizing full-strength signals from two succeeding downstream sensors. In addition, dual sensors are used at each position spanning the desired range of molten metal pool levels to provide redundancy, wherein only the higher temperature of each pair of sensors at a station is utilized.

Effect of mold designs on molten metal behaviour in high-pressure die casting

NASA Astrophysics Data System (ADS)

Ibrahim, M. D.; Rahman, M. R. A.; Khan, A. A.; Mohamad, M. R.; Suffian, M. S. Z. M.; Yunos, Y. S.; Wong, L. K.; Mohtar, M. Z.

2017-04-01

This paper presents a research study conducted in a local automotive component manufacturer that produces aluminium alloy steering housing local and global markets. This study is to investigate the effect of design modification of mold in die casting as to improve the production rate. Design modification is carried out on the casting shot of the mold. Computer flow simulation was carried out to study the flow of molten metal in the mold with respect to the mold design modification. The design parameters of injection speed, die temperature and clamping force has been included in the study. The result of the simulation showed that modifications of casting shot give significant impact towards the molten flow behaviour in casting process. The capabilities and limitations of die casting process simulation to conduct defect analysis had been optimized. This research will enhance the efficiency of the mass production of the industry of die casting with the understanding of defect analysis, which lies on the modification of the mold design, a way early in its stages of production.

PRODUCTION OF HAFNIUM METAL

DOEpatents

Elger, G.W.; Boubel, R.W.

1963-01-01

This patent deals with a process of producing pure Hf metal from oxygen- contaminated gaseous Hf chloride. The oxygen compounds in the chioride gas are halogenated by contacting the gas at elevated temperature with Cl/sub 2/ in the presence of C. The Hf chloride, still in gaseous form, is contacted with molten Mg whereby Hf metal is formed and condensed on the Mg. (AEC)

Mass Producing Targets for Nuclear Fusion

NASA Technical Reports Server (NTRS)

Wang, T. G.; Elleman, D. D.; Kendall, J. M.

1983-01-01

Metal-encapsulating technique advances prospects of controlling nuclear fusion. Prefilled fusion targets form at nozzle as molten metal such as tin flows through outer channel and pressurized deuterium/tritium gas flows through inner channel. Molten metal completely encloses gas charge as it drops off nozzle.

METAL SURFACE TREATMENT

DOEpatents

Eubank, L.D.

1958-08-12

Improved flux baths are described for use in conjunction with hot dipped coatings for uranium. The flux bath consists of molten alkali metal, or alkaline earth metal halides. One preferred embodiment comprises a bath containing molten KCl, NaCl, and LiCl in proportions approximating the triple eutectic.

Analytical Modeling of Plasma Arc Cutting of Steel Plate

NASA Astrophysics Data System (ADS)

Cimbala, John; Fisher, Lance; Settles, Gary; Lillis, Milan

2000-11-01

A transferred-arc plasma torch cuts steel plate, and in the process ejects a molten stream of iron and ferrous oxides ("ejecta"). Under non-optimum conditions - especially during low speed cuts and/or small-radius corner cuts - "dross" is formed. Dross is re-solidified molten metal that sticks to the underside of the cut and renders it rough. The present research is an attempt to analytically model this process, with the goal of predicting dross formation. With the aid of experimental data, a control volume formulation is used in a steady frame of reference to predict the mass flow of molten material inside the cut. Although simple, the model is three-dimensional, can predict the shear stress driving the molten material in the direction of the plasma jet, and can predict the velocity of molten material exiting the bottom of the plate. In order to predict formation of dross, a momentum balance is performed on the flowing melt, considering the resisting viscous and surface tension forces. Preliminary results are promising, and provide a potential means of predicting dross formation without resorting to detailed computational analyses.

Numerical modeling of keyhole dynamics in laser welding

NASA Astrophysics Data System (ADS)

Zhang, Wen-Hai; Zhou, Jun; Tsai, Hai-Lung

2003-03-01

Mathematical models and the associated numerical techniques have been developed to study the following cases: (1) the formation and collapse of a keyhole, (2) the formation of porosity and its control strategies, (3) laser welding with filler metals, and (4) the escape of zinc vapor in laser welding of galvanized steel. The simulation results show that the formation of porosity in the weld is caused by two competing mechanisms: one is the solidification rate of the molten metal and the other is the speed that molten metal backfills the keyhole after laser energy is terminated. The models have demonstrated that porosity can be reduced or eliminated by adding filler metals, controlling laser tailing power, or applying an electromagnetic force during keyhole collapse process. It is found that a uniform composition of weld pool is difficult to achieve by filler metals due to very rapid solidification of the weld pool in laser welding, as compared to that in gas metal arc welding.

Geologic continuous casting below continental and deep-sea detachment faults and at the striated extrusion of Sacsayhuaman, Peru

USGS Publications Warehouse

Spencer, J.E.

1999-01-01

In the common type of industrial continuous casting, partially molten metal is extruded from a vessel through a shaped orifice called a mold in which the metal assumes the cross-sectional form of the mold as it cools and solidifies. Continuous casting can be sustained as long as molten metal is supplied and thermal conditions are maintained. I propose that a similar process produced parallel sets of grooves in three geologic settings, as follows: (1) corrugated metamorphic core complexes where mylonized mid-crustal rocks were exhumed by movement along low-angle normal faults known as detachment faults; (2) corrugated submarine surfaces where ultramafic and mafic rocks were exhumed by normal faulting within oceanic spreading centers; and (3) striated magma extrusions exemplified by the famous grooved outcrops at the Inca fortress of Sacsayhuaman in Peru. In each case, rocks inferred to have overlain the corrugated surface during corrugation genesis molded and shaped a plastic to partially molten rock mass as it was extruded from a moderate- to high-temperature reservoir.

Behavior of toxic metals and radionuclides during molten salt oxidation of chlorinated plastics.

PubMed

Yang, Hee-Chul; Cho, Yong-Jun; Eun, Hee-Chul; Yoo, Jae-Hyung; Kim, Joon-Hyung

2004-01-01

Molten salt oxidation is one of the promising alternatives to incineration for chlorinated organics without the emission of chlorinated organic pollutants. This study investigated the behavior of three hazardous metals (Cd, Pb, and Cr) and four radioactive metal surrogates (Cs, Ce, Gd, and Sm) in the molten Na2CO3 oxidation reactor during the destruction of PVC plastics. In the tested temperature ranges (1143 1223K) and NaCl content (0-10%), the impact of temperature on the retention of cadmium and lead in the molten salt reactor was very small, but that of the NaCl content for their retention was relatively higher. The influence of NaCl accumulation was, however, proven to be practically negligible due to the low-temperature operating characteristics of the molten salt oxidation system. Neither temperature increase nor chlorine accumulation in the MSO reactor reduced the retention of Cr, Ce, Gd, and Sm. Over 99.98% of these metals remained in the reactor. The influence of the temperature on the cesium behavior is relatively large for a chlorine addition, however, over 99.7% of cesium remained in the reactor throughout the entire test. The experimental metal entrainment rate and the entrained metal particle size distribution agree well with the theoretical equilibrium metal distributions.

MELTING AND PURIFICATION OF URANIUM

DOEpatents

Spedding, F.H.; Gray, C.F.

1958-09-16

A process is described for treating uranium ingots having inner metal portions and an outer oxide skin. The method consists in partially supporting such an ingot on the surface of a grid or pierced plate. A sufficient weight of uranium is provided so that when the mass becomes molten, the oxide skin bursts at the unsupported portions of its bottom surface, allowing molten urantum to flow through the burst skin and into a container provided below.

Sidewall containment of liquid metal with horizontal alternating magnetic fields

DOEpatents

Pareg, Walter F.

1990-01-01

An apparatus for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers.

Sidewall containment of liquid metal with horizontal alternating magnetic fields

DOEpatents

Praeg, Walter F.

1995-01-01

An apparatus for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers.

Method for the melting of metals

DOEpatents

White, Jack C.; Traut, Davis E.

1992-01-01

A method of quantitatively determining the molten pool configuration in melting of metals. The method includes the steps of introducing hafnium metal seeds into a molten metal pool at intervals to form ingots, neutron activating the ingots and determining the hafnium location by radiometric means. Hafnium possesses exactly the proper metallurgical and radiochemical properties for this use.

Method for inhibiting alkali metal corrosion of nickel-containing alloys

DOEpatents

DeVan, Jackson H.; Selle, James E.

1983-01-01

Structural components of nickel-containing alloys within molten alkali metal systems are protected against corrosion during the course of service by dissolving therein sufficient aluminum, silicon, or manganese to cause the formation and maintenance of a corrosion-resistant intermetallic reaction layer created by the interaction of the molten metal, selected metal, and alloy.

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

NASA Astrophysics Data System (ADS)

Yang, Nancy; Yee, J.; Zheng, B.; Gaiser, K.; Reynolds, T.; Clemon, L.; Lu, W. Y.; Schoenung, J. M.; Lavernia, E. J.

2017-04-01

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. The study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. The study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. The current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.

The use of molten salts as physical models for the study of solidification in metals and semiconductors

NASA Technical Reports Server (NTRS)

Koziol, Jurek K.; Sadoway, Donald R.

1987-01-01

It is presently noted that molten salts possess attributes rendering them attractive as physical models of cast metals in solidification studies. Molten alkali halides have an approximately correct Prandtl number for this modeling of metallic melts, and are transparent to visible light. Attention is given to solidification in the LiCl-KCl system, in order to determine whether such phenomena as solute rejection can be observed and characterized through the application of laser schlieren imaging.

Method and apparatus for regenerating cold traps within liquid-metal systems

DOEpatents

McKee, Jr., John M.

1976-01-01

Oxide and hydride impurities of a liquid metal such as sodium are removed from a cold trap by heating to a temperature at which the metal hydroxide is stable in a molten state. The partial pressure of hydrogen within the system is measured to determine if excess hydride or oxide is present. Excess hydride is removed by venting hydrogen gas while excess oxide can be converted to molten hydroxide through the addition of hydrogen. The resulting, molten hydroxide is drained from the trap which is then returned to service at cold trap temperatures within the liquid-metal system.

An Assessment of Molten Metal Detachment Hazards for Electron Beam Welding in the Space Environment: Analysis and Test Results

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.; Russell, C.; Bhat, B.; Fragomeni, J. M.

1998-01-01

Conditions under which molten metal detachments might occur in a space welding environment are analyzed. A weld pool detachment parameter specifying conditions for pool detachment by impact is derived and corroborated by experimental evidence. Impact detachment for the pool is unlikely. Impact detachment for a drop of metal on the end of the weld wire may be possible under extreme conditions. Other potential causes of molten metal detachment considered, vaporization pressure forces and wire flickout from the pool, did not appear to present significant detachment threats.

The Reduction of Lunar Regolith by Carbothermal Processing Using Methane

NASA Technical Reports Server (NTRS)

Balasubramaniam, R.; Hegde, U.; Gokoglu, S.

2010-01-01

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans Currently being developed by NASA. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source so that a small zone of molten regolith is established. A continuous flow of methane is maintained over the molten regolith zone. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. It is further processed downstream to ultimately produce oxygen.

The Reduction of Lunar Regolith by Carbothermal Processing Using Methane

NASA Technical Reports Server (NTRS)

Balasubramaniam, R.; Gokoglu, S. A.; Hegde, U.

2010-01-01

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source so that a small zone of molten regolith is established. A continuous flow of methane is maintained over the molten regolith zone. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. It is further processed downstream to ultimately produce oxygen.

Chemical Reactions of Simulated Producer Gas with Molten Tin-Bismuth Alloy

Treesearch

Keith J. Bourne

2012-01-01

A pyrolysis and gasification system utilizing molten metal as an energy carrier has been proposed and the initial stages of its design have been completed. However, there are several fundamental questions that need to be answered before the design of this system can be completed. These questions include: How will the molten metal interact with the products of biomass...

Experimental study of hot cracking at circular welding joints of 42CrMo steel

NASA Astrophysics Data System (ADS)

Zhang, Yan; Chen, Genyu; Chen, Binghua; Wang, Jinhai; Zhou, Cong

2017-12-01

The hot cracking at circular welding joints of quenched and tempered 42CrMo steel were studied. The flow of the molten pool and the solidification process of weld were observed with a high-speed video camera. The information on the variations in the weld temperature was collected using an infrared (IR) thermal imaging system. The metallurgical factors of hot cracking were analyzed via metallographic microscope and scanning electron microscope (SEM). The result shows that leading laser laser-metal active gas (MAG) hybrid welding process has a smaller solid-liquid boundary movement rate (VSL) and a smaller solid-liquid boundary temperature gradient (GSL) compared with leading arc laser-MAG hybrid welding process and laser welding process. Additionally, the metal in the molten pool has superior permeability while flowing toward the dendritic roots and can compensate for the inner-dendritic pressure balance. Therefore, leading laser laser-MAG hybrid welding process has the lowest hot cracking susceptibility.

Process for producing elements from a fused bath using a metal strap and ceramic electrode body nonconsumable electrode assembly

DOEpatents

Byrne, Stephen C.

1984-01-01

A nonconsumable electrode assembly suitable for use in the production of metal by electrolytic reduction of a metal compound dissolved in a molten salt, the assembly comprising a ceramic electrode body and a metal subassembly of a metal conductor rod and at least one metal strap affixed to an end of the rod with opposing portions extending radially outwardly from the rod axis and having the ends of the strap attached to the electrode body.

Process for making structure for a MCFC

DOEpatents

Pasco, Wayne D.; Arendt, Ronald H.

1986-01-01

A process of making a porous carbonate-containing structure for use in a molten carbonate fuel cell, wherein a suitable porous structure is prepared having disposed therein a metal salt selected from the alkali metals and the alkaline earth metals or mixtures thereof with at least a portion of the salt being a monobasic organic acid salt. The monobasic acid salt is converted to the carbonate in situ by heating in the presence of oxygen. Both electrode and electrolyte structures can be prepared. Formic acid is preferred.

Numerical simulation of the alloying process during impulse induction heating of the metal substrate

NASA Astrophysics Data System (ADS)

Popov, V. N.

2017-10-01

2D numerical modeling of the processes during the alloying of the substrate surface metal layer is carried out. Heating, phase transition, heat and mass transfer in the molten metal, solidification of the melt are considered with the aid the proposed mathematical model. Under study is the applicability of the high-frequency electromagnetic field impulse for metal heating and melting. The distribution of the electromagnetic energy in the metal is described by empirical formulas. According to the results of numerical experiments, the flow structure in the melt and distribution of the alloying substances is evaluated.

Sidewall containment of liquid metal with horizontal alternating magnetic fields

DOEpatents

Praeg, W.F.

1995-01-31

An apparatus is disclosed for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers. 19 figs.

Electromagnetic augmentation for casting of thin metal sheets

DOEpatents

Hull, J.R.

1987-10-28

Thin metal sheets are cast by magnetically levitating molten metal deposited in a model within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled by the water-cooled walls of the mold to form a solid metal sheet. A conducting shield is electrically coupled to the molten metal sheet to provide a return path for eddy currents induced in the metal sheet by the current in the AC conducting coils. In another embodiment, a DC conducting coil is coupled to the metal sheet for providing a direct current therein which interacts with the magnetic field to levitate the moving metal sheet. Levitation of the metal sheet in both molten and solid forms reduces its contact pressure with the mold walls while maintaining sufficient engagement therebetween to permit efficient conductive cooling by the mold through which a coolant fluid may be circulated. 8 figs.

Thermodynamic Considerations of Direct Oxygen Removal from Titanium by Utilizing the Deoxidation Capability of Rare Earth Metals

NASA Astrophysics Data System (ADS)

Okabe, Toru H.; Zheng, Chenyi; Taninouchi, Yu-ki

2018-06-01

Oxygen removal from metallic Ti is extremely difficult and, currently, there is no commercial process for effectively deoxidizing Ti or its alloys. The oxygen concentration in Ti scraps is normally higher than that in virgin metals such as in Ti sponges produced by the Kroll process. When scraps are remelted with virgin metals for producing primary ingots of Ti or its alloys, the amount of scrap that can be used is limited owing to the accumulation of oxygen impurities. Future demands of an increase in Ti production and of mitigating environmental impacts require that the amount of scrap recycled as a feed material of Ti ingots should also increase. Therefore, it is important to develop methods for removing oxygen directly from Ti scraps. In this study, we evaluated the deoxidation limit for β-Ti using Y or light rare earth metals (La, Ce, Pr, or Nd) as a deoxidant. Thermodynamic considerations suggest that extra-low-oxygen Ti, with an oxygen concentration of 100 mass ppm or less can be obtained using a molten salt equilibrating with rare earth metals. The results presented herein also indicate that methods based on molten salt electrolysis for producing rare earth metals can be utilized for effectively and directly deoxidizing Ti scraps.

Thermal and mechanical properties of aluminized fabrics for use in ferrous metal handling operations.

PubMed

Wren, J E; Scott, W D; Bates, C E

1977-11-01

Protective garments are normally worn in molten handling operations to provide some protection against molten metal splashes. These garments are also intended to provide protection against radiant heat, and they should be as heat resistant and comfortable as possible. Asbestos-based fabrics have been employed for many years, but recently some concern has been expressed over possible asbestos exposure. This program was undertaken to explore the ability of several types of fabrics to resist heat transfer during molten metal impact. A molten metal splash test, along with standard methods for determining tensile strength, flame resistance, and abrasion-flexing resistance were used to evaluate several classes of protective fabrics. The results indicate that there are materials available that offer equal or better mechanical properties and thermal protection compared to aluminized asbestos.

PREPARATION OF ACTINIDE-ALUMINUM ALLOYS

DOEpatents

Moore, R.H.

1962-09-01

BS>A process is given for preparing alloys of aluminum with plutonium, uranium, and/or thorium by chlorinating actinide oxide dissolved in molten alkali metal chloride with hydrochloric acid, chlorine, and/or phosgene, adding aluminum metal, and passing air and/or water vapor through the mass. Actinide metal is formed and alloyed with the aluminum. After cooling to solidification, the alloy is separated from the salt. (AEC)

Ultra-fast boriding of metal surfaces for improved properties

DOEpatents

Timur, Servet; Kartal, Guldem; Eryilmaz, Osman L.; Erdemir, Ali

2015-02-10

A method of ultra-fast boriding of a metal surface. The method includes the step of providing a metal component, providing a molten electrolyte having boron components therein, providing an electrochemical boriding system including an induction furnace, operating the induction furnace to establish a high temperature for the molten electrolyte, and boriding the metal surface to achieve a boride layer on the metal surface.

The thermodynamics of pyrochemical processes for liquid metal reactor fuel cycles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Johnson, I.

1987-01-01

The thermodynamic basis for pyrochemical processes for the recovery and purification of fuel for the liquid metal reactor fuel cycle is described. These processes involve the transport of the uranium and plutonium from one liquid alloy to another through a molten salt. The processes discussed use liquid alloys of cadmium, zinc, and magnesium and molten chloride salts. The oxidation-reduction steps are done either chemically by the use of an auxiliary redox couple or electrochemically by the use of an external electrical supply. The same basic thermodynamics apply to both the salt transport and the electrotransport processes. Large deviations from idealmore » solution behavior of the actinides and lanthanides in the liquid alloys have a major influence on the solubilities and the performance of both the salt transport and electrotransport processes. Separation of plutonium and uranium from each other and decontamination from the more noble fission product elements can be achieved using both transport processes. The thermodynamic analysis is used to make process design computations for different process conditions.« less

Process for removal of sulfur compounds from fuel gases

DOEpatents

Moore, Raymond H.; Stegen, Gary E.

1978-01-01

Fuel gases such as those produced in the gasification of coal are stripped of sulfur compounds and particulate matter by contact with molten metal salt. The fuel gas and salt are intimately mixed by passage through a venturi or other constriction in which the fuel gas entrains the molten salt as dispersed droplets to a gas-liquid separator. The separated molten salt is divided into a major and a minor flow portion with the minor flow portion passing on to a regenerator in which it is contacted with steam and carbon dioxide as strip gas to remove sulfur compounds. The strip gas is further processed to recover sulfur. The depleted, minor flow portion of salt is passed again into contact with the fuel gas for further sulfur removal from the gas. The sulfur depleted, fuel gas then flows through a solid absorbent for removal of salt droplets. The minor flow portion of the molten salt is then recombined with the major flow portion for feed to the venturi.

30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal. ...

30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2014 CFR

2014-07-01

... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal. ...

30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2012 CFR

2012-07-01

... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal. ...

30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2013 CFR

2013-07-01

... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal. ...

30 CFR 56.15007 - Protective equipment or clothing for welding, cutting, or working with molten metal.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Protective equipment or clothing for welding... METAL AND NONMETAL MINES Personal Protection § 56.15007 Protective equipment or clothing for welding... be worn when welding, cutting, or working with molten metal. ...

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2011 CFR

2011-07-01

... or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2010 CFR

2010-07-01

... or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

Modelisation of the SECMin molten salts environment

NASA Astrophysics Data System (ADS)

Lucas, M.; Slim, C.; Delpech, S.; di Caprio, D.; Stafiej, J.

2014-06-01

We develop a cellular automata modelisation of SECM experiments to study corrosion in molten salt media for generation IV nuclear reactors. The electrodes used in these experiments are cylindrical glass tips with a coaxial metal wire inside. As the result of simulations we obtain the current approach curves of the electrodes with geometries characterized by several values of the ratios of glass to metal area at the tip. We compare these results with predictions of the known analytic expressions, solutions of partial differential equations for flat uniform geometry of the substrate. We present the results for other, more complicated substrate surface geometries e. g. regular saw modulated surface, surface obtained by Eden model process, ...

Drying of fiber webs

DOEpatents

Warren, David W.

1997-01-01

A process and an apparatus for high-intensity drying of fiber webs or sheets, such as newsprint, printing and writing papers, packaging paper, and paperboard or linerboard, as they are formed on a paper machine. The invention uses direct contact between the wet fiber web or sheet and various molten heat transfer fluids, such as liquified eutectic metal alloys, to impart heat at high rates over prolonged durations, in order to achieve ambient boiling of moisture contained within the web. The molten fluid contact process causes steam vapor to emanate from the web surface, without dilution by ambient air; and it is differentiated from the evaporative drying techniques of the prior industrial art, which depend on the uses of steam-heated cylinders to supply heat to the paper web surface, and ambient air to carry away moisture, which is evaporated from the web surface. Contact between the wet fiber web and the molten fluid can be accomplished either by submersing the web within a molten bath or by coating the surface of the web with the molten media. Because of the high interfacial surface tension between the molten media and the cellulose fiber comprising the paper web, the molten media does not appreciately stick to the paper after it is dried. Steam generated from the paper web is collected and condensed without dilution by ambient air to allow heat recovery at significantly higher temperature levels than attainable in evaporative dryers.

PROCESS FOR PREPARING URANIUM METAL

DOEpatents

Prescott, C.H. Jr.; Reynolds, F.L.

1959-01-13

A process is presented for producing oxygen-free uranium metal comprising contacting iodine vapor with crude uranium in a reaction zone maintained at 400 to 800 C to produce a vaporous mixture of UI/sub 4/ and iodine. Also disposed within the maction zone is a tungsten filament which is heated to about 1600 C. The UI/sub 4/, upon contacting the hot filament, is decomposed to molten uranium substantially free of oxygen.

Alkali metal ion battery with bimetallic electrode

DOEpatents

Boysen, Dane A; Bradwell, David J; Jiang, Kai; Kim, Hojong; Ortiz, Luis A; Sadoway, Donald R; Tomaszowska, Alina A; Wei, Weifeng; Wang, Kangli

2015-04-07

Electrochemical cells having molten electrodes having an alkali metal provide receipt and delivery of power by transporting atoms of the alkali metal between electrode environments of disparate chemical potentials through an electrochemical pathway comprising a salt of the alkali metal. The chemical potential of the alkali metal is decreased when combined with one or more non-alkali metals, thus producing a voltage between an electrode comprising the molten the alkali metal and the electrode comprising the combined alkali/non-alkali metals.

Powder-Metallurgy Process And Product

NASA Technical Reports Server (NTRS)

Paris, Henry G.

1988-01-01

Rapid-solidification processing yields alloys with improved properties. Study undertaken to extend favorable property combinations of I/M 2XXX alloys through recently developed technique of rapid-solidification processing using powder metallurgy(P/M). Rapid-solidification processing involves impingement of molten metal stream onto rapidly-spinning chill block or through gas medium using gas atomization technique.

METHOD OF PRODUCING DENSE CONSOLIDATED METALLIC REGULUS

DOEpatents

Magel, T.T.

1959-08-11

A methcd is presented for reducing dense metal compositions while simultaneously separating impurities from the reduced dense metal and casting the reduced parified dense metal, such as uranium, into well consolidated metal ingots. The reduction is accomplished by heating the dense metallic salt in the presence of a reducing agent, such as an alkali metal or alkaline earth metal in a bomb type reacting chamber, while applying centrifugal force on the reacting materials. Separation of the metal from the impurities is accomplished essentially by the incorporation of a constricted passageway at the vertex of a conical reacting chamber which is in direct communication with a collecting chamber. When a centrifugal force is applled to the molten metal and slag from the reduction in a direction collinear with the axis of the constricted passage, the dense molten metal is forced therethrough while the less dense slag is retained within the reaction chamber, resulting in a simultaneous separation of the reduced molten metal from the slag and a compacting of the reduced metal in a homogeneous mass.

Rare Earth Electrochemical Property Measurements and Phase Diagram Development in a Complex Molten Salt Mixture for Molten Salt Recycle

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Jinsuo; Guo, Shaoqiang

Pyroprocessing is a promising alternative for the reprocessing of used nuclear fuel (UNF) that uses electrochemical methods. Compared to the hydrometallurgical reprocessing method, pyroprocessing has many advantages such as reduced volume of radioactive waste, simple waste processing, ability to treat refractory material, and compatibility with fast reactor fuel recycle. The key steps of the process are the electro-refining of the spent metallic fuel in the LiCl-KCl eutectic salt, which can be integrated with an electrolytic reduction step for the reprocessing of spent oxide fuels.

Cermet materials prepared by combustion synthesis and metal infiltration

DOEpatents

Holt, Joseph B.; Dunmead, Stephen D.; Halverson, Danny C.; Landingham, Richard L.

1991-01-01

Ceramic-metal composites (cermets) are made by a combination of self-propagating high temperature combustion synthesis and molten metal infiltration. Solid-gas, solid-solid and solid-liquid reactions of a powder compact produce a porous ceramic body which is infiltrated by molten metal to produce a composite body of higher density. AlN-Al and many other materials can be produced.

Fission product ion exchange between zeolite and a molten salt

NASA Astrophysics Data System (ADS)

Gougar, Mary Lou D.

The electrometallurgical treatment of spent nuclear fuel (SNF) has been developed at Argonne National Laboratory (ANL) and has been demonstrated through processing the sodium-bonded SNF from the Experimental Breeder Reactor-II in Idaho. In this process, components of the SNF, including U and species more chemically active than U, are oxidized into a bath of lithium-potassium chloride (LiCl-KCl) eutectic molten salt. Uranium is removed from the salt solution by electrochemical reduction. The noble metals and inactive fission products from the SNF remain as solids and are melted into a metal waste form after removal from the molten salt bath. The remaining salt solution contains most of the fission products and transuranic elements from the SNF. One technique that has been identified for removing these fission products and extending the usable life of the molten salt is ion exchange with zeolite A. A model has been developed and tested for its ability to describe the ion exchange of fission product species between zeolite A and a molten salt bath used for pyroprocessing of spent nuclear fuel. The model assumes (1) a system at equilibrium, (2) immobilization of species from the process salt solution via both ion exchange and occlusion in the zeolite cage structure, and (3) chemical independence of the process salt species. The first assumption simplifies the description of this physical system by eliminating the complications of including time-dependent variables. An equilibrium state between species concentrations in the two exchange phases is a common basis for ion exchange models found in the literature. Assumption two is non-simplifying with respect to the mathematical expression of the model. Two Langmuir-like fractional terms (one for each mode of immobilization) compose each equation describing each salt species. The third assumption offers great simplification over more traditional ion exchange modeling, in which interaction of solvent species with each other is considered. (Abstract shortened by UMI.)

Optimization of the fiber laser parameters for local high-temperature impact on metal

NASA Astrophysics Data System (ADS)

Yatsko, Dmitrii S.; Polonik, Marina V.; Dudko, Olga V.

2016-11-01

This paper presents the local laser heating process of surface layer of the metal sample. The aim is to create the molten pool with the required depth by laser thermal treatment. During the heating the metal temperature at any point of the molten zone should not reach the boiling point of the main material. The laser power, exposure time and the spot size of a laser beam are selected as the variable parameters. The mathematical model for heat transfer in a semi-infinite body, applicable to finite slab, is used for preliminary theoretical estimation of acceptable parameters values of the laser thermal treatment. The optimization problem is solved by using an algorithm based on the scanning method of the search space (the zero-order method of conditional optimization). The calculated values of the parameters (the optimal set of "laser radiation power - exposure time - spot radius") are used to conduct a series of natural experiments to obtain a molten pool with the required depth. A two-stage experiment consists of: a local laser treatment of metal plate (steel) and then the examination of the microsection of the laser irradiated region. According to the experimental results, we can judge the adequacy of the ongoing calculations within the selected models.

Synthesis of tritium breeder ceramics from metallic lithium

NASA Astrophysics Data System (ADS)

Knitter, R.; Kolb, M. H. H.; Odemer, C.

2012-01-01

For the fabrication of Li-6 enriched ceramic breeder materials for ITER, the availability of Li-6 enriched compounds is limited, and metallic Li-6 is the most widely available compound. As metallic lithium cannot be used directly in ceramic fabrication processes, we investigated different syntheses to obtain lithium orthosilicate or lithium metatitanate directly from molten lithium. In exothermic reactions of molten lithium with silicon, silica, or titania, several intermediate or precursor phases were observed under argon that could easily be transformed to the desired ceramic phases by a subsequent heat treatment under air. The reaction steps and the resulting phases were studied by differential scanning calorimetry and X-ray diffractometry. The synthesis from lithium and silicon seems to be especially suited for the production of larger quantities and has the advantage that silicon is available with a very high grade of purity.

Innovative oxide materials for electrochemical energy conversion and oxygen separation

NASA Astrophysics Data System (ADS)

Belousov, V. V.

2017-10-01

Ion-conducting solid metal oxides are widely used in high-temperature electrochemical devices for energy conversion and oxygen separation. However, liquid metal oxides possessing unique electrochemical properties still remain of limited use. The review demonstrates the potential for practical applications of molten oxides. The transport properties of molten oxide materials are discussed. The emphasis is placed on the chemical diffusion of oxygen in the molten oxide membrane materials for electrochemical energy conversion and oxygen separation. The thermodynamics of these materials is considered. The dynamic polymer chain model developed to describe the oxygen ion transport in molten oxides is discussed. Prospects for further research into molten oxide materials are outlined. The bibliography includes 145 references.

Investigation of Heat Transfer and Magnetohydrodynamic Flow in Electroslag Remelting Furnace Using Vibrating Electrode

NASA Astrophysics Data System (ADS)

Wang, Fang; Wang, Qiang; Lou, Yanchun; Chen, Rui; Song, Zhaowei; Li, Baokuan

2016-01-01

A transient three-dimensional (3D) coupled mathematical model has been developed to understand the effect of a vibrating electrode on the electromagnetic, two-phase flow and temperature fields as well as the solidification in the electroslag remelting (ESR) process. With the magnetohydrodynamic model, the Joule heating and Lorentz force, which are the source terms in the energy and momentum equations, are recalculated at each iteration as a function of the phase distribution. The influence of the vibrating electrode on the formation of the metal droplet is demonstrated by the volume of fluid approach. Additionally, the solidification of the metal is modeled by an enthalpy-based technique, in which the mushy zone is treated as a porous medium with porosity equal to the liquid fraction. The present work is the first attempt to investigate the innovative technology of the ESR process with a vibrating electrode by a transient 3D comprehensive model. A reasonable agreement between the experiment and simulation is obtained. The results indicate that the whole process is presented as a periodic activity. When the metal droplets fall from the tip of the electrode, the horizontal component of velocity will generate electrode vibration. This will lead to the distribution variation of the flow field in the slag layer. The variation of temperature distribution occurs regularly and is periodically accompanied by the behavior of the falling metal droplets. With the decreasing vibrating frequency and amplitude, the relative velocity of the electrode and molten slag increase accordingly. The diameter of the molten droplets, the maximum temperature and the depth of the molten pool gradually become smaller, lower and shallower.

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2014 CFR

2014-07-01

... intermediate or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... intermediate or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2013 CFR

2013-07-01

... intermediate or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

PROCESS FOR REMOVING NOBLE METALS FROM URANIUM

DOEpatents

Knighton, J.B.

1961-01-31

A pyrometallurgical method is given for purifying uranium containing ruthenium and palladium. The uranium is disintegrated and oxidized by exposure to air and then the ruthenium and palladium are extracted from the uranium with molten zinc.

Improving Metal Casting Process

NASA Technical Reports Server (NTRS)

1998-01-01

Don Sirois, an Auburn University research associate, and Bruce Strom, a mechanical engineering Co-Op Student, are evaluating the dimensional characteristics of an aluminum automobile engine casting. More accurate metal casting processes may reduce the weight of some cast metal products used in automobiles, such as engines. Research in low gravity has taken an important first step toward making metal products used in homes, automobiles, and aircraft less expensive, safer, and more durable. Auburn University and industry are partnering with NASA to develop one of the first accurate computer model predictions of molten metals and molding materials used in a manufacturing process called casting. Ford Motor Company's casting plant in Cleveland, Ohio is using NASA-sponsored computer modeling information to improve the casting process of automobile and light-truck engine blocks.

Method and apparatus for semi-solid material processing

DOEpatents

Han, Qingyou [Knoxville, TN; Jian, Xiaogang [Knoxville, TN; Xu, Hanbing [Knoxville, TN; Meek, Thomas T [Knoxville, TN

2009-02-24

A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 .mu.m, and can be easily retrofitted into existing conventional forming machine.

Separation of Calcium Isotopes by Counter-Current Electro-Migration in Molten Salts; SEPARATION DES ISOTOPES DU CALCIUM PAR ELECTRO-MIGRATION A CONTRECOURANT EN SELS FONDUS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Menes, F.; Dirian, G.; Roth, E.

1962-01-01

The method of counter-current electromigration in molten salts was applied to CaBr/sub 2/ with an alkali metal bromide added to the cathode compartment. Enrichments on Ca/sup 46/ greater than a factor of two were obtained at the anode. The mass effect was found to be about 0.06. An estimation of the cost of energy for a process based on this method was made. (auth)

Method and apparatus for semi-solid material processing

DOEpatents

Han, Qingyou [Knoxville, TN; Jian, Xiaogang [Knoxville, TN; Xu, Hanbing [Knoxville, TN; Meek, Thomas T [Knoxville, TN

2009-11-24

A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 .mu.m, and can be easily retrofitted into existing conventional forming maching.

Method and apparatus for semi-solid material processing

DOEpatents

Han, Qingyou [Knoxville, TN; Jian, Xiaogang [Knoxville, TN; Xu, Hanbing [Knoxville, TN; Meek, Thomas T [Knoxville, TN

2007-05-15

A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 .mu.m, and can be easily retrofitted into existing conventional forming machine.

Tolerance requirements to prevent fluid leakage in the crucible/plunger MEA experiment MPS 770030

NASA Technical Reports Server (NTRS)

Rathz, T. J.

1982-01-01

Molten Al-In leaked unexpectedly out of the crucible of a proposed MEA materials processing in space experiment. The molten metals use a spring loaded plunger to eliminate most free surfaces. The critical criteria necessary to initiate flow and the rate of fluid flow into the crucible/plunger annulus is calculated. Experimental in situ X-radiographs are interpreted according to the calculations. A note on possible effects of capillary flow if wetting occurs between crucible/plunger and liquids is included.

Cermet materials prepared by combustion synthesis and metal infiltration

DOEpatents

Holt, J.B.; Dunmead, S.D.; Halverson, D.C.; Landingham, R.L.

1991-01-29

Ceramic-metal composites (cermets) are made by a combination of self-propagating high temperature combustion synthesis and molten metal infiltration. Solid-gas, solid-solid and solid-liquid reactions of a powder compact produce a porous ceramic body which is infiltrated by molten metal to produce a composite body of higher density. AlN-Al and many other materials can be produced. 6 figures.

Purification and Chemical Control of Molten Li2BeF 4 for a Fluoride Salt Cooled Reactor

NASA Astrophysics Data System (ADS)

Kelleher, Brian Christopher

Out of the many proposed generation IV, high-temperature reactors, the molten salt reactor (MSR) is one of the most promising. The first large scale MSR, the molten salt reactor experiment (MSRE), operated from 1965 to 1969 using Li2BeF4, or flibe, as a coolant and solvent for uranium fluoride fuel, at maximum temperatures of 654°C, for over 15000 hours. The MSRE experienced no concept breaking surprises and was considered a success. Newly proposed designs of molten salt reactors use solid fuels, making them less exotic compared to the MSRE. However, any molten salt reactor will require a great deal of research pertaining to the chemical and mechanical mastery of molten salts in order to prepare it for commercialization. To supplement the development of new molten salt reactors, approximately 100 kg of flibe was purified using the standard hydrofluorination process. Roughly half of the purified salt was lithium-7 enriched salt from the secondary loop of the MSRE. Purification rids the salt of impurities and reduces its capacity for corrosion, also known as the redox potential. The redox potential of flibe was measured at various stages of purification for the first time using a dynamic beryllium reference electrode. These redox measurements have been superimposed with metal impurities measurements found by neutron activation analysis. Lastly, reductions of flibe with beryllium metal have been investigated. Over reductions have been performed, which have shown to decrease redox potential while seemingly creating a beryllium-beryllium halide system. Recommendations of the lowest advisable redox potential for corrosion tests are included along with suggestions for future work.

Excimer laser irradiation of metal surfaces

NASA Astrophysics Data System (ADS)

Kinsman, Grant

In this work a new method of enhancing CO2 laser processing by modifying the radiative properties of a metal surface is studied. In this procedure, an excimer laser (XeCl) or KrF) exposes the metal surface to overlapping pulses of high intensity, 10(exp 8) - 10(exp 9) W cm(exp -2), and short pulse duration, 30 nsec FWHM (Full Width Half Maximum), to promote structural and chemical change. The major processing effect at these intensities is the production of a surface plasma which can lead to the formation of a laser supported detonation wave (LSD wave). This shock wave can interact with the thin molten layer on the metal surface influencing to a varying degree surface oxidation and roughness features. The possibility of the expulsion, oxidation and redeposition of molten droplets, leading to the formation of micron thick oxide layers, is related to bulk metal properties and the incident laser intensity. A correlation is found between the expulsion of molten droplets and a Reynolds number, showing the interaction is turbulent. The permanent effects of these interactions on metal surfaces are observed through scanning electron microscopy (SEM), transient calorimetric measurements and Fourier transform infrared (FTIR) spectroscopy. Observed surface textures are related to the scanning procedures used to irradiate the metal surface. Fundamental radiative properties of a metal surface, the total hemispherical emissivity, the near-normal spectral absorptivity, and others are examined in this study as they are affected by excimer laser radiation. It is determined that for heavily exposed Al surface, alpha' (10.6 microns) can be increased to values close to unity. Data relating to material removal rates and chemical surface modification for excimer laser radiation is also discussed. The resultant reduction in the near-normal reflectivity solves the fundamental problem of coupling laser radiation into highly reflective and conductive metals such as copper and aluminum. The increased absorption at 10.6 microns enables enhanced CO2 laser drilling and cutting rates in electrolytic Cu at incident intensities, I(0) of approximately 10(exp 6) W cm(exp -2). Data showing enhanced drilling rates in Al 1100-H14 is also presented. In these regimes the majority of material is removed in the liquid state. The amount of molten material formed can be directly attributed to the enhanced initial coupling of the excimer laser irradiated surface. Previously, to process Cu and Al it has been required to increase I(0) until material removal occurs through vaporization. This fundamental data and analysis provides a basic framework for further work in this new field of study.

Integrated oil production and upgrading using molten alkali metal

DOEpatents

Gordon, John Howard

2016-10-04

A method that combines the oil retorting process (or other process needed to obtain/extract heavy oil or bitumen) with the process for upgrading these materials using sodium or other alkali metals. Specifically, the shale gas or other gases that are obtained from the retorting/extraction process may be introduced into the upgrading reactor and used to upgrade the oil feedstock. Also, the solid materials obtained from the reactor may be used as a fuel source, thereby providing the heat necessary for the retorting/extraction process. Other forms of integration are also disclosed.

Process for producing elements from a fused bath using a metal strap and ceramic electrode body nonconsumable electrode assembly

DOEpatents

Byrne, S.C.

1984-07-03

A nonconsumable electrode assembly is described suitable for use in the production of metal by electrolytic reduction of a metal compound dissolved in a molten salt, the assembly comprising a ceramic electrode body and a metal subassembly of a metal conductor rod and at least one metal strap affixed to an end of the rod with opposing portions extending radially outwardly from the rod axis and having the ends of the strap attached to the electrode body. 7 figs.

Method for forming consumable electrodes from metallic chip scraps

DOEpatents

Girshov, Vladimir Leonidovich; Podpalkin, Arcady Munjyvich; Treschevskiy, Arnold Nikolayevich; Abramov, Alexey Alexandrovich

2005-10-11

The method relates to metallurgical recycling of waste products, preferably titanium alloys chips scrap. Accordingly after crushing and cleaning, the chip scrap is subjected to vacuum-thermal degassing (VTD); the chip scrap is pressed into briquettes; the briquettes are placed into a mould allowing sufficient remaining space for the addition of molten metal alloy; the mould is pre-heated before filling with the molten metal alloy; the mould remaining space is filled with molten metal alloy. After cooling, the electrode is removed from the mould. The method provides a means for 100% use of chip scrap in producing consumable electrodes having increased mechanical strength and reduced interstitial impurities content leading to improved secondary cast alloys.

Riser Feeding Evaluation Method for Metal Castings Using Numerical Analysis

NASA Astrophysics Data System (ADS)

Ahmad, Nadiah

One of the design aspects that continues to create a challenge for casting designers is the optimum design of casting feeders (risers). As liquid metal solidifies, the metal shrinks and forms cavities inside the casting. In order to avoid shrinkage cavities, risers are added to the casting shape to supply additional molten metal when shrinkage occurs during solidification. The shrinkage cavities in the casting are compensated by controlling the cooling rate to promote directional solidification. This control can be achieved by designing the casting such that the cooling begins at the sections that are farthest away from the risers and ends at the risers. Therefore, the risers will solidify last and feed the casting with the molten metal. As a result, the shrinkage cavities formed during solidification are in the risers which are later removed from the casting. Since casting designers have to usually go through iterative processes of validating the casting designs which are very costly due to expensive simulation processes or manual trials and errors on actual casting processes, this study investigates more efficient methods that will help casting designers utilize their casting experiences systematically to develop good initial casting designs. The objective is to reduce the casting design method iterations; therefore, reducing the cost involved in that design processes. The aim of this research aims at finding a method that can help casting designers design effective risers used in sand casting process of aluminum-silicon alloys by utilizing the analysis of solidification simulation. The analysis focuses on studying the significance of pressure distribution of the liquid metal at the early stage of casting solidification, when heat transfer and convective fluid flow are taken into account in the solidification simulation. The mathematical model of casting solidification was solved using the finite volume method (FVM). This study focuses to improve our understanding of the feeding behavior in aluminum-silicon alloys and the effective feeding by considering the pressure gradient distribution of the molten metal at casting dendrite coherency point. For this study, we will identify the relationship between feeding efficiency, shrinkage behavior and how the change in riser size affects the pressure gradient in the casting. This understanding will be used to help in the design of effective risers.

Process of making structure for a MCFC

DOEpatents

Pasco, W.D.; Arendt, R.H.

1985-04-03

A process of making a porous carbonate-containing structure for use in a molten carbonate fuel cell is disclosed, wherein a suitable porous structure is prepared having disposed therein a metal salt selected from the alkali metals and the alkaline earth metals or mixtures thereof with at least a portion of the salt being a monobasic organic acid salt. The monobasic acid salt is converted to the carbonate in situ by heating in the presence of oxygen. Both electrode and electrolyte structures can be prepared. Formic acid is preferred.

Device for determining carbon activity through pressure

DOEpatents

Roche, Michael F.

1976-01-01

A hollow iron capsule of annular shape having an interior layer of Fe.sub.0.947 0 and a near absolute internal vacuum is submersed within a molten metal with the inner chamber of the capsule connected to a pressure sensor. Carbon present in the molten metal diffuses through the capsule wall and reacts with the Fe.sub.0.947 0 layer to generate a CO.sub.2 --CO gas mixture within the internal chamber. The total absolute pressure of the gas measured by the pressure sensor is directly proportional to the carbon activity of the molten metal.

Castable Cement Can Prevent Molten-Salt Corrosion in CSP

DOE Office of Scientific and Technical Information (OSTI.GOV)

2016-09-01

NREL's study demonstrated that castable cements on metals are a protective barrier that can prevent permeation of molten salts toward metallic surfaces. The silica-based castable cement Aremco 645-N, when sprayed with boron nitride, can protect containment metallic alloys from attack by molten chlorides at high temperatures (650 degrees C) in short-term tests. Improved thermal energy storage technology could increase the performance of CSP and reduce costs, helping to reach the goal of the U.S. Department of Energy's SunShot Initiative to make solar cost-competitive with other non-renewable sources of electricity by 2020.

75 FR 6307 - Approval and Promulgation of Air Quality Implementation Plans; Maryland; Control of Carbon...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-02-09

... Oxygen Furnaces AGENCY: Environmental Protection Agency (EPA). ACTION: Direct final rule. SUMMARY: EPA is... carbon monoxide (CO) emissions from basic oxygen furnaces (BOFs) at steel mills in the State of Maryland... blast furnace and scrap metal which is heated with oxygen to produce molten metal. The molten metal is...

The production of oxygen and metal from lunar regolith

NASA Astrophysics Data System (ADS)

Schwandt, Carsten; Hamilton, James A.; Fray, Derek J.; Crawford, Ian A.

2012-12-01

The present article summarises the various methods that have been, and still are, explored for the production of oxygen from lunar materials. These include the classical concepts based on chemical reduction with hydrogen or methane, vapour phase pyrolysis, sulphuric acid treatment, and molten oxide electrolysis. Our main focus in this paper is on a novel approach developed at the University of Cambridge that employs molten salt electrochemistry to achieve the combined winning of oxygen and metal from solid lunar materials of varying composition. This makes the Cambridge process attractive because it will work equally well in mare as in highland regions. We also discuss the implications of the recent apparent discovery of water ice at the poles of the Moon and conclude that, even if this discovery is confirmed, it will nevertheless be desirable to provide oxygen at non-polar localities, and the Cambridge process is a strong candidate for achieving this.

Electrochemical monitoring of high-temperature molten-salt corrosion

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gao, G.; Stott, F.H.; Dawson, J.L.

1990-02-01

Hot molten-salt corrosion can cause serious metal degradation in boiler plant, incinerators, and furnaces. In this research, electrochemical-impedance and electrochemical-noise techniques have been evaluated for the monitoring of hot-corrosion processes in such plants. Tests have been carried out on Ni-1% Co and Alloy 800, a commercial material of interest to operators of industrial plants. Electrochemical-impedance and electrochemical-noise data were compared with the results of metallographic examination of the test alloys and showed reasonable correlation between the electrochemical data and the actual degradation processes. This preliminary work indicated that the electrochemical techniques show considerable promise as instruments for the monitoring ofmore » high-temperature corrosion processes.« less

Gas Atomization of Molten Metal: Part I. Numerical Modeling Conception

DOE Office of Scientific and Technical Information (OSTI.GOV)

Leon, Genaro Perez-de; Lamberti, Vincent E.; Seals, Roland D.

This numerical analysis study entails creating and assessing a model that is capable of simulating molten metal droplets and the production of metal powder during the Gas Atomization (GA) method. The essential goal of this research aims to gather more information on simulating the process of creating metal powder. The model structure and perspective was built through the application of governing equations and aspects that utilized factors such as gas dynamics, droplet dynamics, energy balance, heat transfer, fluid mechanics and thermodynamics that were proposed from previous studies. The model is very simple and can be broken down into having amore » set of inputs to produce outputs. The inputs are the processing parameters such as the initial temperature of the metal alloy, the gas pressure and the size of the droplets. Additional inputs include the selection of the metal alloy and the atomization gas and factoring in their properties. The outputs can be designated by the velocity and thermal profiles of the droplet and gas. These profiles illustrate the speed of both as well as the rate of temperature change or cooling rate of the droplets. Here, the main focus is the temperature change and finding the right parameters to ensure that the metal powder is efficiently produced. Once the model was conceptualized and finalized, it was employed to verify the results of other previous studies.« less

Gas Atomization of Molten Metal: Part I. Numerical Modeling Conception

DOE PAGES

Leon, Genaro Perez-de; Lamberti, Vincent E.; Seals, Roland D.; ...

2016-02-01

This numerical analysis study entails creating and assessing a model that is capable of simulating molten metal droplets and the production of metal powder during the Gas Atomization (GA) method. The essential goal of this research aims to gather more information on simulating the process of creating metal powder. The model structure and perspective was built through the application of governing equations and aspects that utilized factors such as gas dynamics, droplet dynamics, energy balance, heat transfer, fluid mechanics and thermodynamics that were proposed from previous studies. The model is very simple and can be broken down into having amore » set of inputs to produce outputs. The inputs are the processing parameters such as the initial temperature of the metal alloy, the gas pressure and the size of the droplets. Additional inputs include the selection of the metal alloy and the atomization gas and factoring in their properties. The outputs can be designated by the velocity and thermal profiles of the droplet and gas. These profiles illustrate the speed of both as well as the rate of temperature change or cooling rate of the droplets. Here, the main focus is the temperature change and finding the right parameters to ensure that the metal powder is efficiently produced. Once the model was conceptualized and finalized, it was employed to verify the results of other previous studies.« less

Method of producing homogeneous mixed metal oxides and metal-metal oxide mixtures

DOEpatents

Quinby, Thomas C.

1978-01-01

Metal powders, metal oxide powders, and mixtures thereof of controlled particle size are provided by reacting an aqueous solution containing dissolved metal values with excess urea. Upon heating, urea reacts with water from the solution leaving a molten urea solution containing the metal values. The molten urea solution is heated to above about 180.degree. C. whereupon metal values precipitate homogeneously as a powder. The powder is reduced to metal or calcined to form oxide particles. One or more metal oxides in a mixture can be selectively reduced to produce metal particles or a mixture of metal and metal oxide particles.

Drying of fiber webs

DOEpatents

Warren, D.W.

1997-04-15

A process and an apparatus are disclosed for high-intensity drying of fiber webs or sheets, such as newsprint, printing and writing papers, packaging paper, and paperboard or linerboard, as they are formed on a paper machine. The invention uses direct contact between the wet fiber web or sheet and various molten heat transfer fluids, such as liquefied eutectic metal alloys, to impart heat at high rates over prolonged durations, in order to achieve ambient boiling of moisture contained within the web. The molten fluid contact process causes steam vapor to emanate from the web surface, without dilution by ambient air; and it is differentiated from the evaporative drying techniques of the prior industrial art, which depend on the uses of steam-heated cylinders to supply heat to the paper web surface, and ambient air to carry away moisture, which is evaporated from the web surface. Contact between the wet fiber web and the molten fluid can be accomplished either by submersing the web within a molten bath or by coating the surface of the web with the molten media. Because of the high interfacial surface tension between the molten media and the cellulose fiber comprising the paper web, the molten media does not appreciatively stick to the paper after it is dried. Steam generated from the paper web is collected and condensed without dilution by ambient air to allow heat recovery at significantly higher temperature levels than attainable in evaporative dryers. 6 figs.

Enhanced vacuum arc vapor deposition electrode

NASA Technical Reports Server (NTRS)

Weeks, Jack L. (Inventor); Todd, Douglas M. (Inventor)

1999-01-01

A process for forming a thin metal coating on a substrate wherein a gas stream heated by an electrical current impinges on a metallic target in a vacuum chamber to form a molten pool of the metal and then vaporize a portion of the pool, with the source of the heated gas stream being on one side of the target and the substrate being on the other side of the target such that most of the metallic vapor from the target is directed at the substrate.

Study on corrosion of metal materials in nitrate molten salts

NASA Astrophysics Data System (ADS)

Zhai, Wei; Yang, Bo; Li, Maodong; Li, Shiping; Xin, Mingliang; Zhang, Shuanghong; Huang, Guojia

2017-01-01

High temperature molten salts as a heat transfer heat storage medium has been more widely used in the field of concentrated solar thermal power generation. In the thermal heat storage system, metal material stability and performance at high temperatures are of one major limitation in increasing this operating temperature. In this paper, study on corrosion of 321H, 304, 316L, P91 metal materials in modified solar two molten salts. The corrosion kinetics of 304, 316L, 321H, P91 metal material in the modified solar two molten salts at 450°C, 500°C is also investigated. Under the same condition it was found that 304, 321H corroded at a rate of 40% less than P91. Spallation of corrosion products was observed on P91 steel, while no obvious observed on other kinds of stainless steel. Corrosion rates of 304, 321H, and 316L slowly increased with temperature. Oxidation mechanisms little varied with temperature. Corrosion products of metal materials observed at 450°C, 500°C were primarily Fe oxide and Fe, Cr oxide.

Corrosion Behavior of Yttria-Stabilized Zirconia-Coated 9Cr-1Mo Steel in Molten UCl3-LiCl-KCl Salt

NASA Astrophysics Data System (ADS)

Jagadeeswara Rao, Ch.; Venkatesh, P.; Prabhakara Reddy, B.; Ningshen, S.; Mallika, C.; Kamachi Mudali, U.

2017-02-01

For the electrorefining step in the pyrochemical reprocessing of spent metallic fuels of future sodium cooled fast breeder reactors, 9Cr-1Mo steel has been proposed as the container material. The electrorefining process is carried out using 5-6 wt.% UCl3 in LiCl-KCl molten salt as the electrolyte at 500 °C under argon atmosphere. In the present study, to protect the container vessel from hot corrosion by the molten salt, 8-9% yttria-stabilized zirconia (YSZ) ceramic coating was deposited on 9Cr-1Mo steel by atmospheric plasma spray process. The hot corrosion behavior of YSZ-coated 9Cr-1Mo steel specimen was investigated in molten UCl3-LiCl-KCl salt at 600 °C for 100-, 500-, 1000- and 2000-h duration. The results revealed that the weight change in the YSZ-coated specimen was insignificant even after exposure to molten salt for 2000 h, and delamination of coating did not occur. SEM examination showed the lamellar morphology of the YSZ coating after the corrosion test with occluded molten salt. The XRD analysis confirmed the presence of tetragonal and cubic phases of ZrO2, without any phase change. Formation of UO2 in some regions of the samples was evident from XRD results.

A facile molten-salt route to graphene synthesis.

PubMed

Liu, Xiaofeng; Giordano, Cristina; Antonietti, Markus

2014-01-15

Efficient synthetic routes are continuously pursued for graphene in order to implement its applications in different areas. However, direct conversion of simple monomers to graphene through polymerization in a scalable manner remains a major challenge for chemists. Herein, a molten-salt (MS) route for the synthesis of carbon nanostructures and graphene by controlled carbonization of glucose in molten metal chloride is reported. In this process, carbohydrate undergoes polymerization in the presence of strongly interacting ionic species, which leads to nanoporous carbon with amorphous nature and adjustable pore size. At a low precursor concentration, the process converts the sugar molecules (glucose) to rather pure few-layer graphenes. The MS-derived graphenes are strongly hydrophobic and exhibit remarkable selectivity and capacity for absorption of organics. The methodology described may open up a new avenue towards the synthesis and manipulation of carbon materials in liquid media. Copyright © 2013 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

ARTICLES: Thermohydrodynamic models of the interaction of pulse-periodic radiation with matter

NASA Astrophysics Data System (ADS)

Arutyunyan, R. V.; Baranov, V. Yu; Bol'shov, Leonid A.; Malyuta, D. D.; Mezhevov, V. S.; Pis'mennyĭ, V. D.

1987-02-01

Experimental and theoretical investigations were made of the processes of drilling and deep melting of metals by pulsed and pulse-periodic laser radiation. Direct photography of the surface revealed molten metal splashing due to interaction with single CO2 laser pulses. A proposed thermohydrodynamic model was used to account for the experimental results and to calculate the optimal parameters of pulse-periodic radiation needed for deep melting. The melt splashing processes were simulated numerically.

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yang, Nancy; Yee, J.; Zheng, B.

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS processmore » control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.« less

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

DOE PAGES

Yang, Nancy; Yee, J.; Zheng, B.; ...

2016-12-08

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS processmore » control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.« less

Induction furnace testing of the durability of prototype crucibles in a molten metal environment

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jablonski, Paul D.

2005-09-01

Engineered ceramic crucibles are commonly used to contain molten metal. Besides high temperature stability, other desired crucible characteristics include thermal shock resistance, minimal reaction with the molten metal and resistance to attack from the base metal oxide formed during melting. When used in an induction furnace, they can be employed as a “semi-permanent” crucible incorporating a dry ram backup and a ceramic cap. This report covers several 250-lb single melt crucible tests in an air melt induction furnace. These tests consisted of melting a charge of 17-4PH stainless steel, holding the charge molten for two hours before pouring off themore » heat and then subsequently sectioning the crucible to review the extent of erosion, penetration and other physical characteristics. Selected temperature readings were made throughout each melt. Chemistry samples were also taken from each heat periodically throughout the hold. The manganese level was observed to affect the rate of chromium loss in a non-linear fashion.« less

Anode for a secondary, high-temperature electrochemical cell

DOEpatents

Vissers, Donald R.; Tani, Benjamin S.

1976-01-01

A high-temperature, secondary electrochemical cell includes an anode containing lithium, an electrolyte containing lithium ions and a cathode containing a chalcogen material such as sulfur or a metallic sulfide. The anode includes a porous substrate formed of, for instance, a compacted mass of entangled metallic fibers providing interstitial crevices for receiving molten lithium metal. The surfaces of the interstitial crevices are provided with a coating of cobalt metal to enhance the retention of the molten lithium metal within the substrate.

In Situ Solid-Gas Reactivity of Nanoscaled Metal Borides from Molten Salt Synthesis.

PubMed

Gouget, Guillaume; Debecker, Damien P; Kim, Ara; Olivieri, Giorgia; Gallet, Jean-Jacques; Bournel, Fabrice; Thomas, Cyril; Ersen, Ovidiu; Moldovan, Simona; Sanchez, Clément; Carenco, Sophie; Portehault, David

2017-08-07

Metal borides have mostly been studied as bulk materials. The nanoscale provides new opportunities to investigate the properties of these materials, e.g., nanoscale hardening and surface reactivity. Metal borides are often considered stable solids because of their covalent character, but little is known on their behavior under a reactive atmosphere, especially reductive gases. We use molten salt synthesis at 750 °C to provide cobalt monoboride (CoB) nanocrystals embedded in an amorphous layer of cobalt(II) and partially oxidized boron as a model platform to study morphological, chemical, and structural evolutions of the boride and the superficial layer exposed to argon, dihydrogen (H 2 ), and a mixture of H 2 and carbon dioxide (CO 2 ) through a multiscale in situ approach: environmental transmission electron microscopy, synchrotron-based near-ambient-pressure X-ray photoelectron spectroscopy, and near-edge X-ray absorption spectroscopy. Although the material is stable under argon, H 2 triggers at 400 °C decomposition of CoB, leading to cobalt(0) nanoparticles. We then show that H 2 activates CoB for the catalysis of CO 2 methanation. A similar decomposition process is also observed on NiB nanocrystals under oxidizing conditions at 300 °C. Our work highlights the instability under reactive atmospheres of nanocrystalline cobalt and nickel borides obtained from molten salt synthesis. Therefore, we question the general stability of metal borides with distinct compositions under such conditions. These results shed light on the actual species in metal boride catalysis and provide the framework for future applications of metal borides in their stability domains.

Experimental Demonstration of the Molten Oxide Electrolysis Method for Oxygen and Iron Production from Simulated Lunar Materials

NASA Technical Reports Server (NTRS)

Curreri, P. A.; Ethridge, E.; Hudson, S.; Sen, S.

2006-01-01

This paper presents the results of a Marshall Space Flight Center funded effort to conduct an experimental demonstration of the processing of simulated lunar resources by the molten oxide electrolysis (MOE) process to produce oxygen and metal from lunar resources to support human exploration of space. Oxygen extracted from lunar materials can be used for life support and propellant, and silicon and metallic elements produced can be used for in situ fabrication of thin-film solar cells for power production. The Moon is rich in mineral resources, but it is almost devoid of chemical reducing agents, therefore, molten oxide electrolysis, MOE, is chosen for extraction, since the electron is the most practical reducing agent. MOE was also chosen for following reasons. First, electrolytic processing offers uncommon versatility in its insensitivity to feedstock composition. Secondly, oxide melts boast the twin key attributes of highest solubilizing capacity for regolith and lowest volatility of any candidate electrolytes. The former is critical in ensuring high productivity since cell current is limited by reactant solubility, while the latter simplifies cell design by obviating the need for a gas-tight reactor to contain evaporation losses as would be the case with a gas or liquid phase fluoride reagent operating at such high temperatures. In the experiments reported here, melts containing iron oxide were electrolyzed in a low temperature supporting oxide electrolyte (developed by D. Sadoway, MIT).

Modeling metal droplet sprays in spray forming

DOE Office of Scientific and Technical Information (OSTI.GOV)

Muoio, N.G.; Crowe, C.T.; Fritsching, U.

1995-12-31

Spray casting is a process whereby a molten metal stream is atomized and deposited on a substrate. The rapid solidification of the metal droplets gives rise to a fine grain structure and improved material properties. This paper presents a simulation for the fluid and thermal interaction of the fluid and droplets in the spray and the effect on the droplet spray pattern. Good agreement is obtained between the measured and predicted droplet mass flux distribution in the spray.

Wetting and spreading behavior of molten brazing filler metallic alloys on metallic substrate

NASA Astrophysics Data System (ADS)

Kogi, Satoshi; Kajiura, Tetsurou; Hanada, Yukiakira; Miyazawa, Yasuyuki

2014-08-01

Wetting and spreading of molten brazing filler material are important factors that influence the brazing ability of a joint to be brazed. Several investigations into the wetting ability of a brazing filler alloy and its surface tension in molten state, in addition to effects of brazing time and temperature on the contact angle, have been carried out. In general, dissimilar-metals brazing technology and high-performance brazed joint are necessities for the manufacturing field in the near future. Therefore, to address this requirement, more such studies on wetting and spreading of filler material are required for a deeper understanding. Generally, surface roughness and surface conditions affect spreading of molten brazing filler material during brazing. Wetting by and interfacial reactions of the molten brazing filler material with the metallic substrate, especially, affect strongly the spreading of the filler material. In this study, the effects of surface roughness and surface conditions on the spreading of molten brazing filler metallic alloys were investigated. Ag-(40-x)Cu-xIn and Ag- (40-x)Cu-xSn (x=5, 10, 15, 20, 25) alloys were used as brazing filler materials. A mild-steel square plate (S45C (JIS); side: 30 mm; thickness: 3mm) was employed as the substrate. A few surfaces with varying roughness were prepared using emery paper. Brazing filler material and metallic base plate were first washed with acetone, and then a flux was applied to them. The filler, 50 mg, was placed on the center of the metallic base with the flux. A spreading test was performed under Ar gas using an electrically heated furnace, after which, the original spreading area, defined as the sessile drop area, and the apparent spreading area, produced by the capillary grooves, were both evaluated. It was observed that the spreading area decreased with increasing In and Sn content.

Producing Production Level Tooling in Prototype Timing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mc Hugh, Kevin Matthew; Knirsch, J.

A new rapid solidification process machine will be able to produce eight-inch diameter by six-inch thick finished cavities at the rate of one per hour - a rate that will change the tooling industry dramatically. Global Metal Technologies, Inc. (GMTI) (Solon, OH) has signed an exclusive license with Idaho National Engineered and Environmental Laboratories (INEEL) (Idaho Falls, ID) for the development and commercialization of the rapid solidification process (RSP tooling). The first production machine is scheduled for delivery in July 2001. The RSP tooling process is a method of producing production level tooling in prototype timing. The process' inventor, Kevinmore » McHugh, describes it as a rapid solidification method, which differentiates it from the standard spray forming methods. RSP itself is relatively straightforward. Molten metal is sprayed against the ceramic pattern, replicating the pattern's contours, surface texture and details. After spraying, the molten tool steel is cooled at room temperature and separated from the pattern. The irregular periphery of the freshly sprayed insert is squared off, either by machining or, in the case of harder tool steels, by wire EDM. XX« less

Electrochemical devices utilizing molten alkali metal electrode-reactant

DOEpatents

Hitchcock, David C.; Mailhe, Catherine C.; De Jonghe, Lutgard C.

1986-01-01

Electrochemical cells are provided with a reactive metal to reduce the oxide of the alkali metal electrode-reactant. Cells employing a molten alkali metal electrode, e.g., sodium, in contact with a ceramic electrolyte, which is a conductor of the ions of the alkali metal forming the electrode, exhibit a lower resistance when a reactive metal, e.g., vanadium, is allowed to react with and reduce the alkali metal oxide. Such cells exhibit less degradation of the electrolyte and of the glass seals often used to joining the electrolyte to the other components of the cell under cycling conditions.

Electrochemical devices utilizing molten alkali metal electrode-reactant

DOEpatents

Hitchcock, D.C.; Mailhe, C.C.; De Jonghe, L.C.

1985-07-10

Electrochemical cells are provided with a reactive metal to reduce the oxide of the alkali metal electrode-reactant. Cells employing a molten alkali metal electrode, e.g., sodium, in contact with a ceramic electrolyte, which is a conductor of the ions of the alkali metal forming the electrode, exhibit a lower resistance when a reactive metal, e.g., vanadium, is allowed to react with and reduce the alkali metal oxide. Such cells exhibit less degradation of the electrolyte and of the glass seals often used to joining the electrolyte to the other components of the cell under cycling conditions.

Creep resistant, metal-coated LiFeO.sub.2 anodes for molten carbonated fuel cells

DOEpatents

Khandkar, Ashok C.

1994-01-01

A porous, creep-resistant, metal-coated, LiFeO.sub.2 ceramic electrode for fuel cells is disclosed. The electrode is particularly useful for molten carbonate fuel cells (MCFC) although it may have utilities in solid oxide fuel cells (SOFC) as well.

Creep resistant, metal-coated LiFeO[sub 2] anodes for molten carbonated fuel cells

DOEpatents

Khandkar, A.C.

1994-08-23

A porous, creep-resistant, metal-coated, LiFeO[sub 2] ceramic electrode for fuel cells is disclosed. The electrode is particularly useful for molten carbonate fuel cells (MCFC) although it may have utilities in solid oxide fuel cells (SOFC) as well. 11 figs.

Extraction of volatile and metals from extraterrestrial materials

NASA Technical Reports Server (NTRS)

Lewis, John S.

1990-01-01

Since March 1, 1989, attention was concentrated on the extraction of ilmenite from extraterrestrial materials and on the planning and development of laboratory facilities for carbonyl extraction of ferrous metal alloys. Work under three subcontracts was administered by this project: (1) electrolytic production of oxygen from molten lunar materials; (2) microwave processing of lunar materials; and (3) production of a resource-oriented space science data base.

Low-head feeding system for thin section castings

DOEpatents

Daniel, Sabah S.; Kleeb, Thomas R.; Lewis, Thomas W.; McDermott, John F.; Ozgu, Mustafa R.; Padfield, Ralph C.; Rego, Donovan N.; Vassilicos, Achilles

1990-01-01

A feed system is provided for conveying molten metal to a thin section caster having mold surfaces moving exclusively in the direction of casting. The feed system has a passage of circular cross section adjacent to one end thereof for receiving molten metal and a rectangular cross section at the delivery end thereof adjacent to the caster. The feed system is designed for supplying molten metal to the caster at low pressure for "closed-pool" type caster operation. The point of highest elevation in the metal flow passage of the feed system is on the upper surface of a transition portion where the cross section changes from circular to rectangular adjacent to the nozzle. The level or height of the high point above the centerline of the nozzle exit is selected so as to be less than the pressure of the metal measured in inches at the nozzle exit. This feature enables the maintenance of positive pressure in the metal within the feed system so that ingress of air into the metal is prevented.

INTERIOR VIEW, LOOKING EAST, TOWARD BASE OF CUPOLA WITH AN ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

INTERIOR VIEW, LOOKING EAST, TOWARD BASE OF CUPOLA WITH AN IRON POUR IN PROCESS AS CUPOLA TENDERS, BENNY GOODMAN AND ALAN REVER, USING A ROD TO CLEAN OUT THE TAP HOLE ('RODDING THE HOLE') TO KEEP THE MOLTEN METAL FLOWING FREELY FROM THE IRON BOXES AT THE CUPOLA BASE INTO THE IRON TROUGH FOR LADLE TRANSFER TO THE MIXER AND PIPE CASTING OPERATIONS. ACIPCO'S CUPOLA (150 INCH IN DIAMETER AND 72 FEET IN HEIGHT) PRODUCED IRON THAT IS FURTHER REFINED FOR CASTING OPERATIONS. NATURAL GAS IS USED TO RESTART THE CUPOLA AFTER WHICH IT RUNS CONTINUOUSLY USING FURNACE GASES, PRODUCING AN AVERAGE OF 100 TONS OF MOLTEN METAL PER HOUR. - American Cast Iron Pipe Company, Cupola Area, 1501 Thirty-first Avenue North, Birmingham, Jefferson County, AL

Utilization of Space Station for industrial thermophysical property measurements

NASA Astrophysics Data System (ADS)

Overfelt, Tony; Watkins, John

1996-03-01

The International Space Station represents the largest cooperative space project in history and will be industry's only reasonable access to the low-g environment for long duration R&D. Such access will provide unique and competitive capabilities to industry if private sector entities can commercially utilize the Space Station for their industrial research programs. The metal casting industry has identified the need for accurate thermophysical properties of molten alloys as a priority need. Research over the last decade has demonstrated that experimental techniques exist to containerlessly measure critical thermophysical and related properties of molten metals for improved process design. This paper describes the ``VULCAN'' concept, a proposed commercial instrument for thermophysical properties measurements on the Space Station. Finally, several issues regarding private sector utilization of the Space Station are also discussed.

Laser Consolidation - A Novel One-Step Manufacturing Process for Making Net-Shape Functional Components

DTIC Science & Technology

2006-05-01

dies. This process uses a laser beam to melt a controlled amount of injected powder on a base plate to deposit the first layer and on previous passes...Consolidation” to build functional net-shape components directly from metallic powder in one step [1-3]. The laser consolidation is a one-step computer-aided...A focused laser beam is irradiated on the substrate to create a molten pool, while metallic powder is injected simultaneously into the pool. A

Research and Industrial Application of a Process for Direct Reduction of Molten High-Lead Smelting Slag

NASA Astrophysics Data System (ADS)

Li, Weifeng; Zhan, Jing; Fan, Yanqing; Wei, Chang; Zhang, Chuanfu; Hwang, Jiann-Yang

2017-04-01

A pyrometallurgical process for the direct reduction of molten high-lead smelting slag obtained by the Shuikoushan (SKS) method was reported in this article using solid anthracite as the fuel and reductant. The chemical composition, the lead phase composition, and the physical properties of the molten high-lead slag were examined. The effects of the process parameters on the recovery rate of valued metals were investigated in the laboratory. According to the experimental results, a new efficient bottom blow reduction furnace was employed in the pilot-scale test for high-lead slag reduction. The results showed the average recovery rate of lead was more than 96.0% with lower Pb and high Zn content of the reducing slag under the condition of reduction temperature 1100-1200°C, coal ratio 5.5-7.5%, reduction time 90-150 min, CaO/SiO2 ratio 0.35-0.45, and FeO/SiO2 ratio 1.4-1.55. Moreover, nearly 250 kg of standard coal per ton of crude Pb output was reduced compared with the blast furnace reduction process.

Strip casting apparatus and method

DOEpatents

Williams, R.S.; Baker, D.F.

1988-09-20

Strip casting apparatus including a molten-metal-holding container and a nozzle to deposit molten metal onto a moving chill drum to directly cast continuous metallic strip. The nozzle body includes a slot bounded between a back and a front lip. The slot width exceeds about 20 times the gap distance between the nozzle and the chill drum surface. Preferably, the slot width exceeds 0.5 inch. This method of strip casting minimizes pressure drop, insuring better metal-to-chill-drum contact which promotes heat transfer and results in a better quality metallic strip. 6 figs.

Strip casting apparatus and method

DOEpatents

Williams, Robert S.; Baker, Donald F.

1988-01-01

Strip casting apparatus including a molten-metal-holding container and a nozzle to deposit molten metal onto a moving chill drum to directly cast continuous metallic strip. The nozzle body includes a slot bounded between a back and a front lip. The slot width exceeds about 20 times the gap distance between the nozzle and the chill drum surface. Preferably, the slot width exceeds 0.5 inch. This method of strip casting minimizes pressure drop, insuring better metal-to-chill-drum contact which promotes heat transfer and results in a better quality metallic strip.

Compact, Lightweight Electromagnetic Pump for Liquid Metal

NASA Technical Reports Server (NTRS)

Godfroy, Thomas; Palzin, Kurt

2010-01-01

A proposed direct-current electromagnetic pump for circulating a molten alkali metal alloy would be smaller and lighter and would demand less input power, relative to currently available pumps of this type. (Molten alkali metals are used as heat-transfer fluids in high-temperature stages of some nuclear reactors.) The principle of operation of this or any such pump involves exploitation of the electrical conductivity of the molten metal: An electric current is made to pass through the liquid metal along an axis perpendicular to the longitudinal axis of the flow channel, and a magnetic field perpendicular to both the longitudinal axis and the electric current is superimposed on the flowchannel region containing the electric current. The interaction between the electric current and the magnetic field produces the pumping force along the longitudinal axis. The advantages of the proposed pump over other such pumps would accrue from design features that address overlapping thermal and magnetic issues.

Development of Prototype Production ESR Facilities

DTIC Science & Technology

1977-07-01

CJISTHIBUTION STATEMENT (ot (he aUxIr&cl entnred in lil^ck 21), If ctlfferert from Wfv.rtj 18. SiJPPi EMENTARV NOTES M9. Kfc y WORDS...Unlike in conventional foundry methods, electroslag castings are made in water-cooled metal molds by remelting of consumable electrodes in... CONSUMABLE ELECTRODE TOP MOLD SLAQ POOL MOLTEN METAL POOL LEVEL DETECTOR MOLTEN METAL POOL ESP INCrOT COPPER LINER mTER JACKET

Cathode composition for electrochemical cell

DOEpatents

Steunenberg, Robert K.; Martin, Allan E.; Tomczuk, Zygmunt

1976-01-01

A high-temperature, secondary electrochemical cell includes a negative electrode containing an alkali metal such as lithium, an electrolyte of molten salt containing ions of that alkali metal and a positive electrode containing a mixture of metallic sulfides. The positive electrode composition is contained within a porous structure that permits permeation of molten electrolyte and includes a mixture of about 5% to 30% by weight Cu.sub.2 S in FeS.

Benefit from NASA

NASA Image and Video Library

1998-01-01

Don Sirois, an Auburn University research associate, and Bruce Strom, a mechanical engineering Co-Op Student, are evaluating the dimensional characteristics of an aluminum automobile engine casting. More accurate metal casting processes may reduce the weight of some cast metal products used in automobiles, such as engines. Research in low gravity has taken an important first step toward making metal products used in homes, automobiles, and aircraft less expensive, safer, and more durable. Auburn University and industry are partnering with NASA to develop one of the first accurate computer model predictions of molten metals and molding materials used in a manufacturing process called casting. Ford Motor Company's casting plant in Cleveland, Ohio is using NASA-sponsored computer modeling information to improve the casting process of automobile and light-truck engine blocks.

Electrodeposition of Dense Chromium Coatings from Molten Salt Electrolytes

DTIC Science & Technology

1991-04-01

AD-A235 978 . JUN 03 391 ELECTRODEPOSITION OF DENSE CHROMIUM COATINGS FROM MOLTEN SALT ELECTROLYTES Final Technical Report J t ]Vgca or by ~ 4 OTC... molten salts , pulsed currents, electrodeposition. 2. The results, on the electrodeposition of dense chromium coatings from molten salt electrolytes... salts dissolved in molten salts using the cell Cl2/C/!Cr 2 + in LiCI-KCI//Cr metal The chromium ions are introduced by anodizing a piece of chromium and

Ceramic nanostructures and methods of fabrication

DOEpatents

Ripley, Edward B [Knoxville, TN; Seals, Roland D [Oak Ridge, TN; Morrell, Jonathan S [Knoxville, TN

2009-11-24

Structures and methods for the fabrication of ceramic nanostructures. Structures include metal particles, preferably comprising copper, disposed on a ceramic substrate. The structures are heated, preferably in the presence of microwaves, to a temperature that softens the metal particles and preferably forms a pool of molten ceramic under the softened metal particle. A nano-generator is created wherein ceramic material diffuses through the molten particle and forms ceramic nanostructures on a polar site of the metal particle. The nanostructures may comprise silica, alumina, titania, or compounds or mixtures thereof.

Anode composite for molten carbonate fuel cell

DOEpatents

Iacovangelo, Charles D.; Zarnoch, Kenneth P.

1983-01-01

An anode composite useful for a molten carbonate fuel cell comprised of a porous sintered metallic anode component having a porous bubble pressure barrier integrally sintered to one face thereof, said barrier being comprised of metal coated ceramic particles sintered together and to said anode by means of said metal coating, said metal coating enveloping said ceramic particle and being selected from the group consisting of nickel, copper and alloys thereof, the median pore size of the barrier being significantly smaller than that of the anode.

A novel process for recovery of iron, titanium, and vanadium from titanomagnetite concentrates: NaOH molten salt roasting and water leaching processes.

PubMed

Chen, Desheng; Zhao, Longsheng; Liu, Yahui; Qi, Tao; Wang, Jianchong; Wang, Lina

2013-01-15

A novel process for recovering iron, titanium, and vanadium from titanomagnetite concentrates has been developed. In the present paper, the treatment of rich titanium-vanadium slag by NaOH molten salt roasting and water leaching processes is investigated. In the NaOH molten salt roasting process, the metallic iron is oxidized into ferriferous oxide, MgTi(2)O(5) is converted to NaCl-type structure of Na(2)TiO(3), and M(3)O(5) (M=Ti, Mg, Fe) is converted to α-NaFeO(2)-type structure of NaMO(2), respectively. Roasting temperature and NaOH-slag mass ratio played a considerable role in the conversion of titanium in the rich titanium-vanadium slag during the NaOH molten salt roasting process. Roasting at 500 °C for 60 min and a 1:1 NaOH-slag mass ratio produces 96.3% titanium conversion. In the water leaching process, the Na(+) was exchanged with H(+), Na(2)TiO(3) is converted to undefined structure of H(2)TiO(3), and NaMO(2) is converted to α-NaFeO(2)-type structure of HMO(2). Under the optimal conditions, 87.3% of the sodium, 42.3% of the silicon, 43.2% of the aluminum, 22.8% of the manganese, and 96.6% of the vanadium are leached out. Crown Copyright © 2012. Published by Elsevier B.V. All rights reserved.

Relationship between spatter formation and dynamic molten pool during high-power deep-penetration laser welding

NASA Astrophysics Data System (ADS)

Li, Shichun; Chen, Genyu; Katayama, Seiji; Zhang, Yi

2014-06-01

The spatter and the molten pool behavior, which were the important phenomena concerned with the welding quality, were observed and studied by using the high-speed camera and the X-ray transmission imaging system during laser welding under different welding parameters. The formation mechanism of spatter and the corresponding relationships between the spatter and molten pool behavior were investigated. The increase of laser power could cause more intense evaporation and lead to more spatter. When the focal position of laser beam was changed, different forms of spatter were generated, as well as the flow trends of molten metal on the front keyhole wall and at the rear molten pool were changed. The results revealed that the behavior of molten pool, which could be affected by the absorbed energy distribution in the keyhole, was the key factor to determine the spatter formation during laser welding. The relatively sound weld seam could be obtained during laser welding with the focal position located inside the metal.

Controlled temperature expansion in oxygen production by molten alkali metal salts

DOEpatents

Erickson, Donald C.

1985-06-04

A continuous process is set forth for the production of oxygen from an oxygen containing gas stream, such as air, by contacting a feed gas stream with a molten solution of an oxygen acceptor to oxidize the acceptor and cyclically regenerating the oxidized acceptor by releasing oxygen from the acceptor wherein the oxygen-depleted gas stream from the contact zone is treated sequentially to temperature reduction by heat exchange against the feed stream so as to condense out entrained oxygen acceptor for recycle to the process, combustion of the gas stream with fuel to elevate its temperature and expansion of the combusted high temperature gas stream in a turbine to recover power.

Controlled temperature expansion in oxygen production by molten alkali metal salts

DOEpatents

Erickson, D.C.

1985-06-04

A continuous process is set forth for the production of oxygen from an oxygen containing gas stream, such as air, by contacting a feed gas stream with a molten solution of an oxygen acceptor to oxidize the acceptor and cyclically regenerating the oxidized acceptor by releasing oxygen from the acceptor wherein the oxygen-depleted gas stream from the contact zone is treated sequentially to temperature reduction by heat exchange against the feed stream so as to condense out entrained oxygen acceptor for recycle to the process, combustion of the gas stream with fuel to elevate its temperature and expansion of the combusted high temperature gas stream in a turbine to recover power. 1 fig.

Carbothermic Aluminum Production Using Scrap Aluminum As A Coolant

DOEpatents

LaCamera, Alfred F.

2002-11-05

A process for producing aluminum metal by carbothermic reduction of alumina ore. Alumina ore is heated in the presence of carbon at an elevated temperature to produce an aluminum metal body contaminated with about 10-30% by wt. aluminum carbide. Aluminum metal or aluminum alloy scrap then is added to bring the temperature to about 900-1000.degree. C. and precipitate out aluminum carbide. The precipitated aluminum carbide is filtered, decanted, or fluxed with salt to form a molten body having reduced aluminum carbide content.

Carbonate fuel cell anodes

DOEpatents

Donado, R.A.; Hrdina, K.E.; Remick, R.J.

1993-04-27

A molten alkali metal carbonates fuel cell porous anode of lithium ferrite and a metal or metal alloy of nickel, cobalt, nickel/iron, cobalt/iron, nickel/iron/aluminum, cobalt/iron/aluminum and mixtures thereof wherein the total iron content including ferrite and iron of the composite is about 25 to about 80 percent, based upon the total anode, provided aluminum when present is less than about 5 weight percent of the anode. A process is described for production of the lithium ferrite containing anode by slipcasting.

Carbonate fuel cell anodes

DOEpatents

Donado, Rafael A.; Hrdina, Kenneth E.; Remick, Robert J.

1993-01-01

A molten alkali metal carbonates fuel cell porous anode of lithium ferrite and a metal or metal alloy of nickel, cobalt, nickel/iron, cobalt/iron, nickel/iron/aluminum, cobalt/iron/aluminum and mixtures thereof wherein the total iron content including ferrite and iron of the composite is about 25 to about 80 percent, based upon the total anode, provided aluminum when present is less than about 5 weight percent of the anode. A process for production of the lithium ferrite containing anode by slipcasting.

Two techniques enable sampling of filtered and unfiltered molten metals

NASA Technical Reports Server (NTRS)

Burris, L., Jr.; Pierce, R. D.; Tobias, K. R.; Winsch, I. O.

1967-01-01

Filtered samples of molten metals are obtained by filtering through a plug of porous material fitted in the end of a sample tube, and unfiltered samples are obtained by using a capillary-tube extension rod with a perforated bucket. With these methods there are no sampling errors or loss of liquid.

Study of the reaction of tungsten carbide in molten alkali metal nitrates. Syntheses of divalent (s and d blocks) metal tungstates

NASA Astrophysics Data System (ADS)

Deloume, Jean-Pierre; Marote, Pedro; Sigala, Catherine; Matei, Cristian

2003-08-01

WC is tested as precursor to synthesize metal tungstates by reaction in molten alkali metal nitrates. This constitutes a complex redox system with two reducing agents, W and C, and an oxidizer having several oxidation states. The mass loss due to the evolution of gases reveals the reaction steps. The infrared analyses of the gas phase show what kind of reaction develops according to the temperature. WC produces a water-soluble alkali metal tungstate. The reaction of a mixture of WC and a divalent metal chloride (Mg, Ca, Ba, Ni, Cu, Zn) leads to water-insoluble metal tungstates. As the reactivity of the cations increases in the order Zn, Ni, Cu, the reaction of WC is modified by their presence. The physico-chemical characterizations of the products show that some of them are contaminated either by WC or by metal oxide. Some others are rather pure products. These differences, in relationship with the other analyses, allow to propose first reaction pathways of the tungsten carbide in molten salts.

Metal/gas MHD conversion

NASA Astrophysics Data System (ADS)

Thibault, J. P.; Joussellin, F.; Alemany, A.; Dupas, A.

1982-09-01

Operation features, theory, performance, and possible spatial applications of metal/gas MHD electrical generators are described. The working principle comprises an MHD channel, surrounded by a magnet, filled with a molten, highly conductive metal into which gas is pumped. The heat of the metal expands the gas, forcing a flow through the magnetic field crossing the channel, thus creating an electrical current conducted by the metal. The gas and metal are separated by a centrifugal device and both are redirected into the channel, forming thereby a double closed circuit when the heat of the molten metal is returned to the flow. Necessary characteristics for the gas such as a fairly low vaporization temperature and nonmiscibility with the metal, are outlined, and a space system using Li-Cs or Z-K as the heat carrier kept molten by a parabolic dish system is sketched. Equations governing the fluid mechanics, thermodynamics, and the electrical generation are defined. The construction of a prototype MHD generator using a tin-water flow operating at 250 C, a temperature suitable for coupling to solar heat sources, is outlined, noting expected efficiencies of 20-30 percent.

Temperature Dependence of Behavior of Interface Between Molten Sn and LiCl-KCl Eutectic Melt Due to Rising Gas Bubble

NASA Astrophysics Data System (ADS)

Natsui, Shungo; Nashimoto, Ryota; Takai, Hifumi; Kumagai, Takehiko; Kikuchi, Tatsuya; Suzuki, Ryosuke O.

2016-06-01

The behavior of the interface between molten Sn and the LiCl-KCl eutectic melt system was observed directly. We found that the transient behavior of the interface exhibits considerable temperature dependence through a change in its physical properties. The "metal film" generated in the upper molten salt phase significantly influences the shape of the interface. Although the lifetime of the metal film depends on the gas flow rate, it is not affected by the buoyancy if the interfacial tension is dominant.

Method for the safe disposal of alkali metal

DOEpatents

Johnson, Terry R.

1977-01-01

Alkali metals such as those employed in liquid metal coolant systems can be safely reacted to form hydroxides by first dissolving the alkali metal in relatively inert metals such as lead or bismuth. The alloy thus formed is contacted with a molten salt including the alkali metal hydroxide and possibly the alkali metal carbonate in the presence of oxygen. This oxidizes the alkali metal to an oxide which is soluble within the molten salt. The salt is separated and contacted with steam or steam-CO.sub.2 mixture to convert the alkali metal oxide to the hydroxide. These reactions can be conducted with minimal hydrogen evolution and with the heat of reaction distributed between the several reaction steps.

Lifetime of Sodium Beta-Alumina Membranes in Molten Sodium Hydroxide

DTIC Science & Technology

2008-07-01

ABSTRACT Summary: Sodium metal can be made by electrolysis of molten sodium hydroxide in sodium beta-alumina membrane electrolysis cells... electrolysis of molten sodium hydroxide in sodium ”-alumina membrane electrolysis cells. However, there are some uncertainties about the lifetime of the...the properties of the membrane degrade upon long term contact with molten sodium hydroxide. Electrolysis cells were designed, but it proved

Conjugate heat transfer analysis of an ultrasonic molten metal treatment system

NASA Astrophysics Data System (ADS)

Zhu, Youli; Bian, Feilong; Wang, Yanli; Zhao, Qian

2014-09-01

In piezoceramic ultrasonic devices, the piezoceramic stacks may fail permanently or function improperly if their working temperatures overstep the Curie temperature of the piezoceramic material. While the end of the horn usually serves near the melting point of the molten metal and is enclosed in an airtight chamber, so that it is difficult to experimentally measure the temperature of the transducer and its variation with time, which bring heavy difficulty to the design of the ultrasonic molten metal treatment system. To find a way out, conjugate heat transfer analysis of an ultrasonic molten metal treatment system is performed with coupled fluid and heat transfer finite element method. In modeling of the system, the RNG model and the SIMPLE algorithm are adopted for turbulence and nonlinear coupling between the momentum equation and the energy equation. Forced air cooling as well as natural air cooling is analyzed to compare the difference of temperature evolution. Numerical results show that, after about 350 s of working time, temperatures in the surface of the ceramic stacks in forced air cooling drop about 7 K compared with that in natural cooling. At 240 s, The molten metal surface emits heat radiation with a maximum rate of about 19 036 W/m2, while the heat insulation disc absorbs heat radiation at a maximum rate of about 7922 W/m2, which indicates the effectiveness of heat insulation of the asbestos pad. Transient heat transfer film coefficient and its distribution, which are difficult to be measured experimentally are also obtained through numerical simulation. At 240 s, the heat transfer film coefficient in the surface of the transducer ranges from -17.86 to 20.17 W/(m2 · K). Compared with the trial and error method based on the test, the proposed research provides a more effective way in the design and analysis of the temperature control of the molten metal treatment system.

Aluminum base alloy powder metallurgy process and product

NASA Technical Reports Server (NTRS)

Paris, Henry G. (Inventor)

1986-01-01

A metallurgical method including cooling molten aluminum particles and consolidating resulting solidified particles into a multiparticle body, wherein the improvement comprises the provision of greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn. Aluminum containing greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn.

Effects of shielding gas composition on arc profile and molten pool dynamics in gas metal arc welding of steels

NASA Astrophysics Data System (ADS)

Wang, L. L.; Lu, F. G.; Wang, H. P.; Murphy, A. B.; Tang, X. H.

2014-11-01

In gas metal arc welding, gases of different compositions are used to produce an arc plasma, which heats and melts the workpiece. They also protect the workpiece from the influence of the air during the welding process. This paper models gas metal arc welding (GMAW) processes using an in-house simulation code. It investigates the effects of the gas composition on the temperature distribution in the arc and on the molten pool dynamics in gas metal arc welding of steels. Pure argon, pure CO2 and different mixtures of argon and CO2 are considered in the study. The model is validated by comparing the calculated weld profiles with physical weld measurements. The numerical calculations reveal that gas composition greatly affects the arc temperature profile, heat transfer to the workpiece, and consequently the weld dimension. As the CO2 content in the shielding gas increases, a more constricted arc plasma with higher energy density is generated as a result of the increased current density in the arc centre and increased Lorentz force. The calculation also shows that the heat transferred from the arc to the workpiece increases with increasing CO2 content, resulting in a wider and deeper weld pool and decreased reinforcement height.

Magnesia-stabilised zirconia solid electrolyte assisted electrochemical investigation of iron ions in a SiO2-CaO-MgO-Al2O3 molten slag at 1723 K.

PubMed

Gao, Yunming; Yang, Chuanghuang; Zhang, Canlei; Qin, Qingwei; Chen, George Z

2017-06-21

Production of metallic iron through molten oxide electrolysis using inert electrodes is an alternative route for fast ironmaking without CO 2 emissions. The fact that many inorganic oxides melt at ultrahigh temperatures (>1500 K) challenges conventional electro-analytical techniques used in aqueous, organic and molten salt electrolytes. However, in order to design a feasible and effective electrolytic process, it is necessary to best understand the electrochemical properties of iron ions in molten oxide electrolytes. In this work, a magnesia-stabilised zirconia (MSZ) tube with a closed end was used to construct an integrated three-electrode cell with a "MSZ|Pt|O 2 (air)" assembly functioning as the solid electrolyte, the reference electrode and also the counter electrode. Electrochemical reduction of iron ions was systematically investigated on an iridium (Ir) wire working electrode in a SiO 2 -CaO-MgO-Al 2 O 3 molten slag at 1723 K by cyclic voltammetry (CV), square wave voltammetry (SWV), chronopotentiometry (CP) and potentiostatic electrolysis (PE). The results show that the electroreduction of the Fe 2+ ion to Fe on the Ir electrode in the molten slag follows a single two-electron transfer step, and the rate of the process is diffusion controlled. The peak current on the obtained CVs is proportional to the concentration of the Fe 2+ ion in the molten slag and the square root of scan rate. The diffusion coefficient of Fe 2+ ions in the molten slag containing 5 wt% FeO at 1723 K was derived to be (3.43 ± 0.06) × 10 -6 cm 2 s -1 from CP analysis. However, a couple of subsequent processes, i.e. alloy formation on the Ir electrode surface and interdiffusion, were found to affect the kinetics of iron deposition. An ECC mechanism is proposed to account for the CV observations. The findings from this work confirm that zirconia-based solid electrolytes can play an important role in electrochemical fundamental research in high temperature molten slag electrolytes.

Understanding the reliability of solder joints used in advanced structural and electronics applications: Part 1 - Filler metal properties and the soldering process

DOE PAGES

Vianco, Paul T.

2017-02-01

Soldering technology has made tremendous strides in the past half-century. Whether structural or electronic, all solder joints must provide a level of reliability that is required by the application. This Part 1 report examines the effects of filler metal properties and soldering process on joint reliability. Solder alloy composition must have the appropriate melting and mechanical properties that suit the product's assembly process(es) and use environment. The filler metal must also optimize solderability (wetting-and-spreading) to realize the proper joint geometry. Here, the soldering process also affects joint reliability. The choice of flux and thermal profile support the solderability performance ofmore » the molten filler metal to successfully fill the gap and complete the fillet.« less

Effects of Casting Conditions on End Product Defects in Direct Chill Casted Hot Rolling Ingots

NASA Astrophysics Data System (ADS)

Yorulmaz, Arda; Yüksel, Çağlar; Erzi, Eraz; Dispinar, Derya

Direct chill casting is a reliable casting process for almost any wrought aluminum alloy for subsequent deformation via hot rolling to supply vital industries such as aerospace, automotive, construction, packaging and maritime. While some defects occur during casting, like hot tearing, some others like surface defect causing blisters, appear after hot rolling process or annealing after final cold rolling steps. It was found that some of these defects are caused by melt impurities formed from entrained folded aluminum oxides or bifilms. A study in a hot rolling casting facility was carried out with different melt cleaning practices, launder and molten metal transferring designs. Bifilm index and reduced pressure test were used for determining melt cleanliness measurement. It was found that porous plug gas diffusons for degassing are more effective than lance type degassers and a design towards less turbulent molten metal flow from furnace to mould cavity are necessary for reducing defects caused by bifilms.

Ceramic susceptor for induction bonding of metals, ceramics, and plastics

NASA Technical Reports Server (NTRS)

Fox, Robert L.; Buckley, John D.

1991-01-01

A thin (.005) flexible ceramic susceptor (carbon) was discovered. It was developed to join ceramics, plastics, metals, and combinations of these materials using a unique induction heating process. Bonding times for laboratory specimens comparing state of the art technology to induction bonding were cut by a factor of 10 to 100 times. This novel type of carbon susceptor allows for applying heat directly and only to the bondline without heating the entire structure, supports, and fixtures of a bonding assembly. The ceramic (carbon film) susceptor produces molten adhesive or matrix material at the bond interface. This molten material flows through the perforated susceptor producing a fusion between the two parts to be joined, which in many instances has proven to be stronger than the parent material. Bonding can be accomplished in 2 minutes on areas submitted to the inductive heating. Because a carbon susceptor is used in bonding carbon fiber reinforced plastics and ceramics, there is no radar signature or return making it an ideal process for joining advanced aerospace composite structures.

Method and apparatus for spraying molten materials

DOEpatents

Glovan, R.J.; Tierney, J.C.; McLean, L.L.; Johnson, L.L.; Nelson, G.L.; Lee, Y.M.

1996-06-25

A metal spray apparatus is provided with a supersonic nozzle. Molten metal is injected into a gas stream flowing through the nozzle under pressure. By varying the pressure of the injected metal, the droplet can be made in various selected sizes with each selected size having a high degree of size uniformity. A unique one piece graphite heater provides easily controlled uniformity of temperature in the nozzle and an attached tundish which holds the pressurized molten metal. A unique U-shaped gas heater provides extremely hot inlet gas temperatures to the nozzle. A particularly useful application of the spray apparatus is coating of threads of a fastener with a shape memory alloy. This permits a fastener to be easily inserted and removed but provides for a secure locking of the fastener in high temperature environments. 12 figs.

Reversible electro-optic device employing aprotic molten salts and method

DOEpatents

Warner, Benjamin P [Los Alamos, NM; McCleskey, T Mark [Los Alamos, NM; Burrell, Anthony K [Los Alamos, NM; Hall, Simon B [Palmerston North, NZ

2008-01-08

A single-compartment reversible mirror device having a solution of aprotic molten salt, at least one soluble metal-containing species comprising metal capable of being electrodeposited, and at least one anodic compound capable of being oxidized was prepared. The aprotic molten salt is liquid at room temperature and includes lithium and/or quaternary ammonium cations, and anions selected from trifluoromethylsulfonate (CF.sub.3SO.sub.3.sup.-), bis(trifluoromethylsulfonyl)imide ((CF.sub.3SO.sub.2).sub.2N.sup.-), bis(perfluoroethylsulfonyl)imide ((CF.sub.3CF.sub.2SO.sub.2).sub.2N.sup.-) and tris(trifluoromethylsulfonyl)methide ((CF.sub.3SO.sub.2).sub.3C.sup.-). A method for preparing substantially pure molten salts is also described.

Reversible Electro-Optic Device Employing Aprotic Molten Salts And Method

DOEpatents

Warner, Benjamin P.; McCleskey, T. Mark; Burrell, Anthony K.; Hall, Simon B.

2005-03-01

A single-compartment reversible mirror device having a solution of aprotic molten salt, at least one soluble metal-containing species comprising metal capable of being electrodeposited, and at least one anodic compound capable of being oxidized was prepared. The aprotic molten salt is liquid at room temperature and includes lithium and/or quaternary ammonium cations, and anions selected from trifluoromethylsulfonate (CF.sub.3 SO.sub.3.sup.-), bis(trifluoromethylsulfonyl)imide ((CF.sub.3 SO.sub.2).sub.2 N.sup.-), bis(perfluoroethylsulfonyl)imide ((CF.sub.3 CF.sub.2 SO.sub.2).sub.2 N.sup.-) and tris(trifluoromethylsulfonyl)methide ((CF.sub.3 SO.sub.2).sub.3 C.sup.-). A method for preparing substantially pure molten salts is also described.

Electrolysis of metal oxides in MgCl2 based molten salts with an inert graphite anode.

PubMed

Yuan, Yating; Li, Wei; Chen, Hualin; Wang, Zhiyong; Jin, Xianbo; Chen, George Z

2016-08-15

Electrolysis of solid metal oxides has been demonstrated in MgCl2-NaCl-KCl melt at 700 °C taking the electrolysis of Ta2O5 as an example. Both the cathodic and anodic processes have been investigated using cyclic voltammetry, and potentiostatic and constant voltage electrolysis, with the cathodic products analysed by XRD and SEM and the anodic products by GC. Fast electrolysis of Ta2O5 against a graphite anode has been realized at a cell voltage of 2 V, or a total overpotential of about 400 mV. The energy consumption was about 1 kW h kgTa(-1) with a nearly 100% Ta recovery. The cathodic product was nanometer Ta powder with sizes of about 50 nm. The main anodic product was Cl2 gas, together with about 1 mol% O2 gas and trace amounts of CO. The graphite anode was found to be an excellent inert anode. These results promise an environmentally-friendly and energy efficient method for metal extraction by electrolysis of metal oxides in MgCl2 based molten salts.

Infiltration processing of boron carbide-, boron-, and boride-reactive metal cermets

DOEpatents

Halverson, Danny C.; Landingham, Richard L.

1988-01-01

A chemical pretreatment method is used to produce boron carbide-, boron-, and boride-reactive metal composites by an infiltration process. The boron carbide or other starting constituents, in powder form, are immersed in various alcohols, or other chemical agents, to change the surface chemistry of the starting constituents. The chemically treated starting constituents are consolidated into a porous ceramic precursor which is then infiltrated by molten aluminum or other metal by heating to wetting conditions. Chemical treatment of the starting constituents allows infiltration to full density. The infiltrated precursor is further heat treated to produce a tailorable microstructure. The process at low cost produces composites with improved characteristics, including increased toughness, strength.

CO2 decomposition using electrochemical process in molten salts

NASA Astrophysics Data System (ADS)

Otake, Koya; Kinoshita, Hiroshi; Kikuchi, Tatsuya; Suzuki, Ryosuke O.

2012-08-01

The electrochemical decomposition of CO2 gas to carbon and oxygen gas in LiCl-Li2O and CaCl2-CaO molten salts was studied. This process consists of electrochemical reduction of Li2O and CaO, as well as the thermal reduction of CO2 gas by the respective metallic Li and Ca. Two kinds of ZrO2 solid electrolytes were tested as an oxygen ion conductor, and the electrolytes removed oxygen ions from the molten salts to the outside of the reactor. After electrolysis in both salts, the aggregations of nanometer-scale amorphous carbon and rod-like graphite crystals were observed by transmission electron microscopy. When 9.7 %CO2-Ar mixed gas was blown into LiCl-Li2O and CaCl2-CaO molten salts, the current efficiency was evaluated to be 89.7 % and 78.5 %, respectively, by the exhaust gas analysis and the supplied charge. When a solid electrolyte with higher ionic conductivity was used, the current and carbon production became larger. It was found that the rate determining step is the diffusion of oxygen ions into the ZrO2 solid electrolyte.

Experimental characterization of the weld pool flow in a TIG configuration

NASA Astrophysics Data System (ADS)

Stadler, M.; Masquère, M.; Freton, P.; Franceries, X.; Gonzalez, J. J.

2014-11-01

Tungsten Inert Gas (TIG) welding process relies on heat transfer between plasma and work piece leading to a metallic weld pool. Combination of different forces produces movements on the molten pool surface. One of our aims is to determine the velocity on the weld pool surface. This provides a set of data that leads to a deeper comprehension of the flow behavior and allows us to validate numerical models used to study TIG parameters. In this paper, two diagnostic methods developed with high speed imaging for the determination of velocity of an AISI 304L stainless steel molten pool are presented. Application of the two methods to a metallic weld pool under helium with a current intensity of 100 A provides velocity values around 0.70 m/s which are in good agreement with literature works.

Lunar mining of oxygen using fluorine

NASA Technical Reports Server (NTRS)

Burt, Donald M.; Tyburczy, James A.; Roberts, Jeffery J.; Balasubramanian, Rajan

1992-01-01

Experiments during the first year of the project were directed towards generating elemental fluorine via the electrolysis of anhydrous molten fluorides. Na2SiF6 was dissolved in either molten NaBF4 or a eutectic (minimum-melting) mixture of KF-LiF-NaF and electrolyzed between 450 and 600 C to Si metal at the cathode and F2 gas at the anode. Ar gas was continuously passed through the system and F2 was trapped in a KBr furnace. Various anode and cathode materials were investigated. Despite many experimental difficulties, the capability of the process to produce elemental fluorine was demonstrated.

An Interconnected Network of Core-Forming Melts Produced by Shear Deformation

NASA Technical Reports Server (NTRS)

Bruhn, D.; Groebner, N.; Kohlstedt, D. L.

2000-01-01

The formation mechanism of terrestrial planetary is still poorly understood, and has been the subject of numerous experimental studies. Several mechanisms have been proposed by which metal-mainly iron with some nickel-could have been extracted from a silicate mantle to form the core. Most recent models involve gravitational sinking of molten metal or metal sulphide through a partially or fully molten mantle that is often referred to as a'magma ocean. Alternative models invoke percolation of molten metal along an interconnected network (that is, porous flow) through a solid silicate matrix. But experimental studies performed at high pressures have shown that, under hydrostatic conditions, these melts do not form an interconnected network, leading to the widespread assumption that formation of metallic cores requires a magma ocean. In contrast, here we present experiments which demonstrate that shear deformation to large strains can interconnect a significant fraction of initially isolated pockets of metal and metal sulphide melts in a solid matrix of polycrystalline olivine. Therefore, in a dynamic (nonhydrostatic) environment, percolation remains a viable mechanism for the segregation and migration of core-forming melts in a solid silicate mantle.

Non-Contact Temperature Requirements (NCTM) for drop and bubble physics

NASA Technical Reports Server (NTRS)

Hmelo, Anthony B.; Wang, Taylor G.

1989-01-01

Many of the materials research experiments to be conducted in the Space Processing program require a non-contaminating method of manipulating and controlling weightless molten materials. In these experiments, the melt is positioned and formed within a container without physically contacting the container's wall. An acoustic method, which was developed by Professor Taylor G. Wang before coming to Vanderbilt University from the Jet Propulsion Laboratory, has demonstrated the capability of positioning and manipulating room temperature samples. This was accomplished in an earth-based laboratory with a zero-gravity environment of short duration. However, many important facets of high temperature containerless processing technology have not been established yet, nor can they be established from the room temperature studies, because the details of the interaction between an acoustic field an a molten sample are largely unknown. Drop dynamics, bubble dynamics, coalescence behavior of drops and bubbles, electromagnetic and acoustic levitation methods applied to molten metals, and thermal streaming are among the topics discussed.

Conductor of high electrical current at high temperature in oxygen and liquid metal environment

DOEpatents

Powell, IV, Adam Clayton; Pati, Soobhankar; Derezinski, Stephen Joseph; Lau, Garrett; Pal, Uday B.; Guan, Xiaofei; Gopalan, Srikanth

2016-01-12

In one aspect, the present invention is directed to apparatuses for and methods of conducting electrical current in an oxygen and liquid metal environment. In another aspect, the invention relates to methods for production of metals from their oxides comprising providing a cathode in electrical contact with a molten electrolyte, providing a liquid metal anode separated from the cathode and the molten electrolyte by a solid oxygen ion conducting membrane, providing a current collector at the anode, and establishing a potential between the cathode and the anode.

Materials Testing for an Accelerator-Driven Subcritical Molten Salt Fission System: A look at the Materials Science of Molten Salt Corrosion

NASA Astrophysics Data System (ADS)

Sooby, Elizabeth; Balachandran, Shreyas; Foley, David; Hartwig, Karl; McIntyre, Peter; Phongikaroon, Supathorn; Pogue, Nathaniel; Simpson, Michael; Tripathy, Prabhat

2011-10-01

For an accelerator-driven subcritical molten salt fission core to survive its 50+ year fuel life, the primary vessel, heat exchanger, and various internal components must be made of materials that resist corrosion and radiation damage in a high-temperature environment, (500-800 C). An experimental study of the corrosion behavior of candidate metals in contact with molten salt is being conducted at the Center for Advanced Energy Studies. Initial experiments have been run on Nb, Ta, Ni, two zirconium alloys, Hastelloy-N, and a series of steel alloys to form a base line for corrosion in both chloride and bromide salt. Metal coupons were immersed in LiCl-KCl or LiBr-KBr at 700 C in an inert-atmosphere. Salt samples were extracted on a time schedule over a 24-hr period. The samples were analyzed using inductively coupled plasma-mass spectrometry to determine concentrations of metals from corrosion. Preliminary results will be presented.

Electrochemical power-producing cell. [Li/Se

DOEpatents

Cairns, E.J.; Chilenskas, A.A.; Steunenberg, R.K.; Shimotake, H.

1972-05-30

An electrochemical power-producing cell including a molten lithium metal anode, a molten selenium metal cathode, a paste electrolyte separating the anode from the cathode, an anode current collector, and a single layer of niobium expanded metal formed in corrugated shape as cathode current collector is described. In addition, means are provided for sealing the anode and the cathode from loss of lithium and selenium, respectively, and an insulator is provided between the anode housing and the paste electrolyte disk.

Numerical Modeling of Fiber-Reinforced Metal Matrix Composite Processing by the Liquid Route: Literature Contribution

NASA Astrophysics Data System (ADS)

Lacoste, Eric; Arvieu, Corinne; Mantaux, Olivier

2018-04-01

One of the technologies used to produce metal matrix composites (MMCs) is liquid route processing. One solution is to inject a liquid metal under pressure or at constant rate through a fibrous preform. This foundry technique overcomes the problem of the wettability of ceramic fibers by liquid metal. The liquid route can also be used to produce semiproducts by coating a filament with a molten metal. These processes involve physical phenomena combined with mass and heat transfer and phase change. The phase change phenomena related to solidification and also to the melting of the metal during the process notably result in modifications to the permeability of porous media, in gaps in impregnation, in the appearance of defects (porosities), and in segregation in the final product. In this article, we provide a state-of-the-art review of numerical models and simulation developed to study these physical phenomena involved in MMC processing by the liquid route.

Iron aluminides and nickel aluminides as materials for chemical air separation

DOEpatents

Kang, Doohee

1991-01-01

The present invention is directed to a chemical air separation process using a molten salt solution of alkali metal nitrate and nitrite wherein the materials of construction of the containment for the process are chosen from intermetallic alloys of nickel and/or iron aluminide wherein the aluminum content is 28 atomic percent or greater to impart enhanced corrosion resistance.

Iron aluminides and nickel aluminides as materials for chemical air separation

DOEpatents

Kang, D.

1991-01-29

The present invention is directed to a chemical air separation process using a molten salt solution of alkali metal nitrate and nitrite wherein the materials of construction of the containment for the process are chosen from intermetallic alloys of nickel and/or iron aluminide wherein the aluminum content is 28 atomic percent or greater to impart enhanced corrosion resistance.

Recycling Titanium and Its Alloys by Utilizing Molten Salt

NASA Astrophysics Data System (ADS)

Okabe, Toru H.; Taninouchi, Yu-ki

It is commonly believed that the deoxidation of titanium (Ti), or the direct removal of oxygen (O) dissolved in metallic Ti, is practically impossible when magnesium (Mg) is used as the deoxidizing agent. In recent years, it has been experimentally demonstrated that O dissolved in Ti can be directly removed using MgCl2 molten salt electrolysis. By the electrochemical deoxidation technique, Ti wires containing 0.12 mass% O were deoxidized to less than 0.02 mass% O. In some cases, the concentration of O in the Ti wires was reduced to the level of 0.01 mass% O, which cannot be attained using the current Kroll process. The possible application of this deoxidation technique to practical industrial recycling processes is also discussed.

APPARATUS FOR THE PRODUCTION OF LITHIUM METAL

DOEpatents

Baker, P.S.; Duncan, F.R.; Greene, H.B.

1961-08-22

Methods and apparatus for the production of high-purity lithium from lithium halides are described. The apparatus is provided for continuously contacting a molten lithium halide with molten barium, thereby forming lithium metal and a barium halide, establishing separate layers of these reaction products and unreacted barium and lithium halide, and continuously withdrawing lithium and barium halide from the reaction zone. (AEC)

Oxygen production by molten alkali metal salts using multiple absorption-desorption cycles

DOEpatents

Cassano, Anthony A.

1985-01-01

A continuous chemical air separation is performed wherein oxygen is recovered with a molten alkali metal salt oxygen acceptor in a series of absorption zones which are connected to a plurality of desorption zones operated in separate parallel cycles with the absorption zones. A greater recovery of high pressure oxygen is achieved at reduced power requirements and capital costs.

Liquid surface skimmer apparatus for molten lithium and method

DOEpatents

Robinson, Samuel C.; Pollard, Roy E.; Thompson, William F.; Stark, Marshall W.; Currin, Jr., Robert T.

1995-01-01

This invention relates to an apparatus for separating two fluids having different specific gravities. The invention also relates to a method for using the separating apparatus of the present invention. This invention particularly relates to the skimming of molten lithium metal from the surface of a fused salt electrolyte in the electrolytic production of lithium metal from a mixed fused salt.

Potentiometric Sensor for Real-Time Remote Surveillance of Actinides in Molten Salts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Natalie J. Gese; Jan-Fong Jue; Brenda E. Serrano

2012-07-01

A potentiometric sensor is being developed at the Idaho National Laboratory for real-time remote surveillance of actinides during electrorefining of spent nuclear fuel. During electrorefining, fuel in metallic form is oxidized at the anode while refined uranium metal is reduced at the cathode in a high temperature electrochemical cell containing LiCl-KCl-UCl3 electrolyte. Actinides present in the fuel chemically react with UCl3 and form stable metal chlorides that accumulate in the electrolyte. This sensor will be used for process control and safeguarding of activities in the electrorefiner by monitoring the concentrations of actinides in the electrolyte. The work presented focuses onmore » developing a solid-state cation conducting ceramic sensor for detecting varying concentrations of trivalent actinide metal cations in eutectic LiCl-KCl molten salt. To understand the basic mechanisms for actinide sensor applications in molten salts, gadolinium was used as a surrogate for actinides. The ß?-Al2O3 was selected as the solid-state electrolyte for sensor fabrication based on cationic conductivity and other factors. In the present work Gd3+-ß?-Al2O3 was prepared by ion exchange reactions between trivalent Gd3+ from GdCl3 and K+-, Na+-, and Sr2+-ß?-Al2O3 precursors. Scanning electron microscopy (SEM) was used for characterization of Gd3+-ß?-Al2O3 samples. Microfocus X-ray Diffraction (µ-XRD) was used in conjunction with SEM energy dispersive X-ray spectroscopy (EDS) to identify phase content and elemental composition. The Gd3+-ß?-Al2O3 materials were tested for mechanical and chemical stability by exposing them to molten LiCl-KCl based salts. The effect of annealing on the exchanged material was studied to determine improvements in material integrity post ion exchange. The stability of the ß?-Al2O3 phase after annealing was verified by µ-XRD. Preliminary sensor tests with different assembly designs will also be presented.« less

40 CFR 420.121 - Specialized definitions.

Code of Federal Regulations, 2014 CFR

2014-07-01

... AND STANDARDS IRON AND STEEL MANUFACTURING POINT SOURCE CATEGORY Hot Coating Subcategory § 420.121 Specialized definitions. (a) The term galvanizing means coating steel products with zinc by the hot dip... products with terne metal by the hot dip process including the immersion of the steel product in a molten...

40 CFR 420.121 - Specialized definitions.

Code of Federal Regulations, 2013 CFR

2013-07-01

... AND STANDARDS IRON AND STEEL MANUFACTURING POINT SOURCE CATEGORY Hot Coating Subcategory § 420.121 Specialized definitions. (a) The term galvanizing means coating steel products with zinc by the hot dip... products with terne metal by the hot dip process including the immersion of the steel product in a molten...

40 CFR 420.121 - Specialized definitions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... AND STANDARDS IRON AND STEEL MANUFACTURING POINT SOURCE CATEGORY Hot Coating Subcategory § 420.121 Specialized definitions. (a) The term galvanizing means coating steel products with zinc by the hot dip... products with terne metal by the hot dip process including the immersion of the steel product in a molten...

PREPARATION OF URANIUM-ALUMINUM ALLOYS

DOEpatents

Moore, R.H.

1962-09-01

A process is given for preparing uranium--aluminum alloys from a solution of uranium halide in an about equimolar molten alkali metal halide-- aluminum halide mixture and excess aluminum. The uranium halide is reduced and the uranium is alloyed with the excess aluminum. The alloy and salt are separated from each other. (AEC)

Gallium-bearing sphalerite in a metal-sulfide nodule of the Qingzhen (EH3) chondrite

NASA Technical Reports Server (NTRS)

Rambaldi, E. R.; Rajan, R. S.; Housley, R. M.; Wang, D.

1986-01-01

The composition and possible history of the Qingshen (EH3) chondrite is presented. The chondrite contains a population of spheroidal metal-sulfide nodules, which display textural evidence of reheating and melting. Evidence of metal sulfuration is also present, suggesting replacement of metal by sulfide during melting. This process has led to the nucleation of perryite along metal-sulfide interfaces. The Ga-bearing sphalerite that was found may have formed by injection of molten sulfide droplets into the metal followed by subsolidus diffusion of Ga from the metal into the sulfide. The latter may occur because of Ga supersaturation in the metal during progressive sulfuration and its decreased affinity for the metal phase during cooling below the taenite-kamacite transition point.

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in the Space Shuttle Bay at LEO for the International Space Welding Experiment

NASA Technical Reports Server (NTRS)

Fragomeni, James M.

1996-01-01

In 1997, the United States [NASA] and the Paton Electric Welding Institute are scheduled to cooperate in a flight demonstration on the U.S. Space Shuttle to demonstrate the feasibility of welding in space for a possible repair option for the International Space Station Alpha. This endeavor, known as the International Space Welding Experiment (ISWE), will involve astronauts performing various welding exercises such as brazing, cutting, welding, and coating using an electron beam space welding system that was developed by the E.O. Paton Electric Welding Institute (PWI), Kiev Ukraine. This electron beam welding system known as the "Universal Weld System" consists of hand tools capable of brazing, cutting, autogeneous welding, and coating using an 8 kV (8000 volts) electron beam. The electron beam hand tools have also been developed by the Paton Welding Institute with greater capabilities than the original hand tool, including filler wire feeding, to be used with the Universal Weld System on the U.S. Space Shuttle Bay as part of ISWE. The hand tool(s) known as the Ukrainian Universal Hand [Electron Beam Welding] Tool (UHT) will be utilized for the ISWE Space Shuttle flight welding exercises to perform welding on various metal alloy samples. A total of 61 metal alloy samples, which include 304 stainless steel, Ti-6AI-4V, 2219 aluminum, and 5456 aluminum alloys, have been provided by NASA for the ISWE electron beam welding exercises using the UHT. These samples were chosen to replicate both the U.S. and Russian module materials. The ISWE requires extravehicular activity (EVA) of two astronauts to perform the space shuttle electron beam welding operations of the 61 alloy samples. This study was undertaken to determine if a hazard could exist with ISWE during the electron beam welding exercises in the Space Shuttle Bay using the Ukrainian Universal Weld System with the UHT. The safety issue has been raised with regard to molten metal detachments as a result of several possible causes such as welder procedural error, externally applied impulsive forces(s), filler wire entrainment and snap-out, cutting expulsion, and puddle expulsion. Molten metal detachment from either the weld/cut substrate or weld wire could present harm to a astronaut in the space environment it the detachment was ti burn through the fabric of the astronaut Extravehicular Mobility Unit (EMC). In this paper an experimental test was performed in a 4 ft. x 4 ft. vacuum chamber at MSFC enabling protective garment to be exposed to the molten metal drop detachments to over 12 inches. The chamber was evacuated to vacuum levels of at least 1 x 10(exp -5) torr (50 micro-torr) during operation of the 1.0 kW Universal Hand Tool (UHT). The UHT was manually operated at the power mode appropriate for each material and thickness. The space suit protective welding garment, made of Teflon fabric (10 oz. per yard) with a plain weave, was placed on the floor of the vacuum chamber to catch the molten metal drop detachments. A pendulum release mechanism consisting of four hammers, each weighing approximately 3.65 lbs, was used to apply an impact forces to the weld sample/plate during both the electron beam welding and cutting exercises. Measurements were made of the horizontal fling distances of the detached molten metal drops. The volume of a molten metal drop can also be estimated from the size of the cut. Utilizing equations, calculations were made to determine chande in surafec area (Delat a(surface)) for 304 stainless steel for cutting based on measurements of metal drop sizes at the cut edges. For the cut sample of 304 stainless steel based on measurement of the drop size at the edge, Delta-a(surface) was determined to be 0.0054 2 in . Calculations have indicated only a small amount of energy is required to detach a liquid metal drop. For example, approximately only 0.000005 ft-lb of energy is necessary to detach a liquid metal steel drop based on the above theoretical analysis. However, some of the energy will be absorbed by the plate before it reaches the metal drop. Based on the theoretical calculations, it was determined that during a weld cutting exercise, the titanium alloy would be the most difficult to detach molten metal droplets followed by stainless steel and then by aluminum. The results of the experimental effort have shown that molten metal will detach if large enough of a hammer blow is applied to the weld sample plate during the full penetration welding and cutting exercises. However, no molten metal detachments occurred as a result of the filler wire snap-out tests from the weld puddle since it was too difficult to cause the metal to flick-out from the pool. Molten metal detachments, though not large in size, did result from the direct application of the electron beam on the end of the filler weld wire.

Improved Sand-Compaction Method for Lost-Foam Metal Casting

NASA Technical Reports Server (NTRS)

Bakhtiyarov, Sayavur I.; Overfelt, Ruel A.

2008-01-01

An improved method of filling a molding flask with sand and compacting the sand around a refractory-coated foam mold pattern has been developed for incorporation into the lost-foam metal-casting process. In comparison with the conventional method of sand filling and compaction, this method affords more nearly complete filling of the space around the refractory-coated foam mold pattern and more thorough compaction of the sand. In so doing, this method enables the sand to better support the refractory coat under metallostatic pressure during filling of the mold with molten metal.

ELECTROLYSIS OF THORIUM AND URANIUM

DOEpatents

Hansen, W.N.

1960-09-01

An electrolytic method is given for obtaining pure thorium, uranium, and thorium-uranium alloys. The electrolytic cell comprises a cathode composed of a metal selected from the class consisting of zinc, cadmium, tin, lead, antimony, and bismuth, an anode composed of at least one of the metals selected from the group consisting of thorium and uranium in an impure state, and an electrolyte composed of a fused salt containing at least one of the salts of the metals selected from the class consisting of thorium, uranium. zinc, cadmium, tin, lead, antimony, and bismuth. Electrolysis of the fused salt while the cathode is maintained in the molten condition deposits thorium, uranium, or thorium-uranium alloys in pure form in the molten cathode which thereafter may be separated from the molten cathode product by distillation.

Economical Fabrication of Thick-Section Ceramic Matrix Composites

NASA Technical Reports Server (NTRS)

Babcock, Jason; Ramachandran, Gautham; Williams, Brian; Benander, Robert

2010-01-01

A method was developed for producing thick-section [>2 in. (approx.5 cm)], continuous fiber-reinforced ceramic matrix composites (CMCs). Ultramet-modified fiber interface coating and melt infiltration processing, developed previously for thin-section components, were used for the fabrication of CMCs that were an order of magnitude greater in thickness [up to 2.5 in. (approx.6.4 cm)]. Melt processing first involves infiltration of a fiber preform with the desired interface coating, and then with carbon to partially densify the preform. A molten refractory metal is then infiltrated and reacts with the excess carbon to form the carbide matrix without damaging the fiber reinforcement. Infiltration occurs from the inside out as the molten metal fills virtually all the available void space. Densification to <5 vol% porosity is a one-step process requiring no intermediate machining steps. The melt infiltration method requires no external pressure. This prevents over-infiltration of the outer surface plies, which can lead to excessive residual porosity in the center of the part. However, processing of thick-section components required modification of the conventional process conditions, and the means by which the large amount of molten metal is introduced into the fiber preform. Modification of the low-temperature, ultraviolet-enhanced chemical vapor deposition process used to apply interface coatings to the fiber preform was also required to accommodate the high preform thickness. The thick-section CMC processing developed in this work proved to be invaluable for component development, fabrication, and testing in two complementary efforts. In a project for the Army, involving SiC/SiC blisk development, nominally 0.8 in. thick x 8 in. diameter (approx. 2 cm thick x 20 cm diameter) components were successfully infiltrated. Blisk hubs were machined using diamond-embedded cutting tools and successfully spin-tested. Good ply uniformity and extremely low residual porosity (<2 percent) were achieved, the latter being far lower than that achieved with SiC matrix composites fabricated via CVI or PIP. The pyrolytic carbon/zirconium nitride interface coating optimized in this work for use on carbon fibers was incorporated in the SiC/SiC composites and yielded a >41 ksi (approx. 283 MPa) flexural strength.

Low temperature oxidation using support molten salt catalysts

DOEpatents

Weimer, Alan W.; Czerpak, Peter J.; Hilbert, Patrick M.

2003-05-20

Molten salt reactions are performed by supporting the molten salt on a particulate support and forming a fluidized bed of the supported salt particles. The method is particularly suitable for combusting hydrocarbon fuels at reduced temperatures, so that the formation NO.sub.x species is reduced. When certain preferred salts are used, such as alkali metal carbonates, sulfur and halide species can be captured by the molten salt, thereby reducing SO.sub.x and HCl emissions.

TWO-WAY FREEZE VALVE

DOEpatents

Lantz, K.D.; Clark, P.M.

1960-01-01

A valve for closing off the flow of radioactive and corrosive gases and liquids or mixtures thereof and forming a leak tight barrier is described. This valve has no mechanical moving parts which would require design to close tolerances and retention of the usual seal tighthess. Instead, there is provided a cavity in which a fusible metal is contained. Heating and cooling are provided to exercise control over the state of the metal. Baffle chambers are utilized to separate the molten fusible metal from the gas or liquid which is being passed through and return the molten metal to its cavity.

Numerical simulation of heat transfer and fluid flow during double-sided laser beam welding of T-joints for aluminum aircraft fuselage panels

NASA Astrophysics Data System (ADS)

Yang, Zhibin; Tao, Wang; Li, Liqun; Chen, Yanbin; Shi, Chunyuan

2017-06-01

In comparison with conventional laser beam welding, double-sided laser beam welding has two laser heat sources simultaneously and symmetrically loaded from both sides makes it to be a more complicated coupled heat transport and fluid flow process. In this work, in order to understand the heat transfer and fluid flow, a three-dimensional model was developed and validated with the experimental results. The temperature field, fluid flow field, and keyhole characteristic were calculated using the developed model by FLUENT software. Calculated results indicated that the temperature and fluid flow fields were bilateral symmetry along the stringer center, and the molten pool maximum length was located near the keyhole intersection position. The skin side had higher temperature and faster cooling speed. Several characteristic flow patterns in the weld pool cross section, including the vortexes flows near the keyhole opening position, the convection flows above the keyhole intersection location, the regularity downward flows at the molten pool bottom. And in the lengthwise section, a distinct vortex flow below the keyhole, and the liquid metal behind the keyhole first flowed to near the molten pool maximum length location and then to the molten pool surface. Perpendicular to and along welding direction the keyhole liquid metal flowed to the weld molten pool surface and around the keyhole, respectively. The special temperature fields and fluid flow patterns were closely related to the effects of the double sides' laser energy coupling and enhancement. The calculated weld pool geometry basically in good agreement with the experimental results indicated that the developed model was validity and reasonable.

Oxygen production by molten alkali metal salts using multiple absorption-desorption cycles

DOEpatents

Cassano, A.A.

1985-07-02

A continuous chemical air separation is performed wherein oxygen is recovered with a molten alkali metal salt oxygen acceptor in a series of absorption zones which are connected to a plurality of desorption zones operated in separate parallel cycles with the absorption zones. A greater recovery of high pressure oxygen is achieved at reduced power requirements and capital costs. 3 figs.

Survey of Materials for Fusion Fission Hybrid Reactors Vol 1 Rev. 0

DOE Office of Scientific and Technical Information (OSTI.GOV)

Farmer, Joseph Collin

2007-07-03

Materials for fusion-fission hybrid reactors fall into several broad categories, including fuels, blanket and coolant materials, cladding, structural materials, shielding, and in the specific case of inertial-confinement fusion systems, laser and optical materials. This report surveys materials in all categories of materials except for those required for lasers and optics. Preferred collants include two molten salt mixtures known as FLIBE (Li2BeF4) and FLINABE (LiNaBeF4). In the case of homogenous liquid fuels, UF4 can be dissolved in these molten salt mixtures. The transmutation of lithium in this coolant produces very corrosive hydrofluoric acid species (HF and TF), which can rapidly degrademore » structural materials. Broad ranges of high-melting radiation-tolerant structural material have been proposed for fusion-fission reactor structures. These include a wide variety of steels and refractory alloys. Ferritic steels with oxide-dispersion strengthening and graphite have been given particular attention. Refractory metals are found in Groups IVB and VB of the periodic table, and include Nb, Ta, Cr, Mo, and W, as serve as the basis of refractory alloys. Stable high-melting composites and amorphous metals may also be useful. Since amorphous metals have no lattice structure, neutron bombardment cannot dislodge atoms from lattice sites, and the materials would be immune from this specific mode of degradation. The free energy of formation of fluorides of the alloying elements found in steels and refractory alloys can be used to determine the relative stability of these materials in molten salts. The reduction of lithium transmutation products (H + and T +) drives the electrochemical corrosion process, and liberates aggressive fluoride ions that pair with ions formed from dissolved structural materials. Corrosion can be suppressed through the use of metallic Be and Li, though the molten salt becomes laden with colloidal suspensions of Be and Li corrosion products in the process. Alternatively, imposed currents and other high-temperature cathodic protection systems are envisioned for protection of the structural materials. This novel concept could prove to be enabling technology for such high-temperature molten-salt reactors. The use of UF 4 as a liquid-phase homogenous fuel is also complicated by redox control. For example, the oxidation of tetravalent uranium to hexavalent uranium could result in the formation of volatile UF 6. This too could be controlled through electrochemically manipulated oxidation and reduction reactions. In situ studies of pertinent electrochemical reactions in the molten salts are proposed, and are relevant to both the corrosive attack of structural materials, as well as the volatilization of fuel. Some consideration is given to the potential advantages of gravity fed falling-film blankets. Such systems may be easier to control than vortex systems, but would require that cylindrical reaction vessels be oriented with the centerline normal to the gravitational field.« less

Phase separation of metal-added corium and its effect on a steam explosion

NASA Astrophysics Data System (ADS)

Min, B. T.; Kim, J. H.; Hong, S. W.; Hong, S. H.; Park, I. K.; Song, J. H.; Kim, H. D.

2008-07-01

To simulate a relocation of molten core material and its interaction phenomenon with water during a severe accident in a nuclear reactor, a typical corium of UO 2/ZrO 2/Zr/Stainless steel mixed at a 62 wt%, 15 wt%, 12 wt% and 11 wt%, respectively, was melted and then cooled down to become a solidified ingot. It was shown that the molten corium was separated into two layers, of which the upper layer was oxide mixtures and the lower layer was metal alloys. The upper layer was UO 2 and ZrO 2 and the lower layer mostly consisted of metal mixtures such as uranium, zirconium and stainless steel. Iron content varied with the positions and about a half of it existed as an alloy such as Fe 2U. Uranium metal was produced by reduction of UO 2 by zirconium metal. The average densities of the upper oxide layer and the lower metal layer were 8.802 and 9.411 g/cm 3, respectively. In another test, metal-added molten corium was poured into water and it showed that a steam explosion could occur by applying an external trigger.

An interconnected network of core-forming melts produced by shear deformation

PubMed

Bruhn; Groebner; Kohlstedt

2000-02-24

The formation mechanism of terrestrial planetary cores is still poorly understood, and has been the subject of numerous experimental studies. Several mechanisms have been proposed by which metal--mainly iron with some nickel--could have been extracted from a silicate mantle to form the core. Most recent models involve gravitational sinking of molten metal or metal sulphide through a partially or fully molten mantle that is often referred to as a 'magma ocean'. Alternative models invoke percolation of molten metal along an interconnected network (that is, porous flow) through a solid silicate matrix. But experimental studies performed at high pressures have shown that, under hydrostatic conditions, these melts do not form an interconnected network, leading to the widespread assumption that formation of metallic cores requires a magma ocean. In contrast, here we present experiments which demonstrate that shear deformation to large strains can interconnect a significant fraction of initially isolated pockets of metal and metal sulphide melts in a solid matrix of polycrystalline olivine. Therefore, in a dynamic (non-hydrostatic) environment, percolation remains a viable mechanism for the segregation and migration of core-forming melts in a solid silicate mantle.

Fuel conditioning facility electrorefiner start-up results

DOE Office of Scientific and Technical Information (OSTI.GOV)

Goff, K.M.; Mariani, R.D.; Vaden, D.

1996-05-01

At ANL-West, there are several thousand kilograms of metallic spent nuclear fuel containing bond sodium. This fuel will be treated in the Fuel Conditioning Facility (FCF) at ANL-West to produce stable waste forms for storage and disposal. The treatment operations will make use of an electrometallurgical process employing molten salts and liquid metals. The treatment equipment is presently undergoing testing with depleted uranium. Operations with irradiated fuel will commence when the environmental evaluation for FCF is complete.

Chronopotentiometry of Refractory Metals, Actinides and Oxyanions in Molten Salts: A Review

DTIC Science & Technology

1992-09-01

disappaared. No new wave appeared which could be attributed to the nitrosonium , NO+, ion . The nitronium ion , N02+, could not be detected in the melt...electrodeposit- ion of coherent deposits of refractory metals from solutions in fused electrolytes. 2.1. Titanium. The electrochemical oxidation of Ti(II...the higher valent niobium ions were found to be electroactive. The reduction process was a reversible, one electron step with the product soluble in the

49 CFR 174.86 - Maximum allowable operating speed.

Code of Federal Regulations, 2014 CFR

2014-10-01

... Handling of Placarded Rail Cars, Transport Vehicles and Freight Containers § 174.86 Maximum allowable operating speed. (a) For molten metals and molten glass shipped in packagings other than those prescribed in...

49 CFR 174.86 - Maximum allowable operating speed.

Code of Federal Regulations, 2013 CFR

2013-10-01

... Handling of Placarded Rail Cars, Transport Vehicles and Freight Containers § 174.86 Maximum allowable operating speed. (a) For molten metals and molten glass shipped in packagings other than those prescribed in...

49 CFR 174.86 - Maximum allowable operating speed.

Code of Federal Regulations, 2012 CFR

2012-10-01

... Handling of Placarded Rail Cars, Transport Vehicles and Freight Containers § 174.86 Maximum allowable operating speed. (a) For molten metals and molten glass shipped in packagings other than those prescribed in...

Advances in Molten Oxide Electrolysis for the Production of Oxygen and Metals from Lunar Regolith

NASA Technical Reports Server (NTRS)

Sadoway, Donald R.; Sirk, Aislinn; Sibille, Laurent; Melendez, Orlando; Lueck, Dale; Curreri, Peter; Dominquez, Jesus; Whitlow, Jonathan

2008-01-01

As part of an In-Situ Resource Utilization infrastructure to sustain long term-human presence on the lunar surface, the production of oxygen and metals by electrolysis of lunar regolith has been the subject of major scrutiny. There is a reasonably large body of literature characterizing the candidate solvent electrolytes, including ionic liquids, molten salts, fluxed oxides, and pure molten regolith itself. In the light of this information and in consideration of available electrolytic technologies, the authors have determined that direct molten oxide electrolysis at temperatures of approx 1600 C is the most promising avenue for further development. Results from ongoing studies as well as those of previous workers will be presented. Topics include materials selection and testing, electrode stability, gas capture and analysis, and cell operation during feeding and tapping.

Development of High-Temperature Transport Technologies of Molten Salt Slurry in Pyrometallurgical Reprocessing

NASA Astrophysics Data System (ADS)

Hijikata, Takatoshi; Koyama, Tadafumi

Pyrometallurgical-reprocessing is one of the most promising technologies for advanced fuel cycle with favorable economic potential and intrinsic proliferation resistance. The development of transport technology for molten salt is a key issue in the industrialization of pyro-reprocessing. As for pure molten LiCl-KCl eutectic salt at approximately 773 K, we have already reported the successful results of transport using gravity and a centrifugal pump. However, molten salt in an electrorefiner mixes with insoluble fines when spent fuel is dissolved in porous anode basket. The insoluble consists of noble metal fission products, such as Pd, Ru, Mo, and Zr. There have been very few transport studies of a molten salt slurry (metal fines-molten salt mixture). Hence, transport experiments on a molten salt slurry were carried out to investigate the behavior of the slurry in a tube. The apparatus used in the transport experiments on the molten salt slurry consisted of a supply tank, a 10° inclined transport tube (10 mm inner diameter), a valve, a filter, and a recovery tank. Stainless steel (SS) fines with diameters from 53 to 415 μm were used. To disperse these fines homogenously, the molten salt and fines were stirred in the supply tank by an impeller at speeds from 1200 to 2100 rpm. The molten salt slurry containing 0.04 to 0.4 vol.% SS fines was transported from the supply tank to the recovery tank through the transportation tube. In the recovery tank, the fines were separated from the molten salt by the filter to measure the transport behavior of molten salt and SS fines. When the velocity of the slurry was 0.02 m/s, only 1% of the fines were transported to the recovery tank. On the other hand, most of the fines were transported when the velocity of the slurry was more than 0.8 m/s. Consequently, the molten salt slurry can be transported when the velocity is more than 0.8 m/s.

Electrolyte treatment for aluminum reduction

DOEpatents

Brown, Craig W.; Brooks, Richard J.; Frizzle, Patrick B.; Juric, Drago D.

2002-01-01

A method of treating an electrolyte for use in the electrolytic reduction of alumina to aluminum employing an anode and a cathode, the alumina dissolved in the electrolyte, the treating improving wetting of the cathode with molten aluminum during electrolysis. The method comprises the steps of providing a molten electrolyte comprised of ALF.sub.3 and at least one salt selected from the group consisting of NaF, KF and LiF, and treating the electrolyte by providing therein 0.004 to 0.2 wt. % of a transition metal or transition metal compound for improved wettability of the cathode with molten aluminum during subsequent electrolysis to reduce alumina to aluminum.

Experimental program on nucleation and structure in undercooled melts

NASA Technical Reports Server (NTRS)

1982-01-01

Undercooling and structural refinements in droplets of molten metal levitated in an induction field and/or by dispersion in a fluid carrier were studied. Nickel base and lower melting point alloys levitated in molten carrier fluids are considered. The dispersion of molten alloy droplets in a high temperature fluid following the procedures developed by Perepezko and co-workers for lower melting point alloys; obtaining a similar dispersion by room temperature mechanical mixing of particles of the metal and solidified liquid carrier; and solidification of single relatively large droplets in a transparent fluid carrier, enabling high-speed temperature measurement of the recalescence and subsequent cooling behavior are described.

Time-resolved in situ powder X-ray diffraction reveals the mechanisms of molten salt synthesis.

PubMed

Moorhouse, Saul J; Wu, Yue; Buckley, Hannah C; O'Hare, Dermot

2016-11-24

We report the first use of high-energy monochromatic in situ X-ray powder diffraction to gain unprecedented insights into the chemical processes occurring during high temperature, lab-scale metal oxide syntheses. During the flux synthesis of the n = 4 Aurivillius phase, Bi 5 Ti 3 Fe 0.5 Cr 0.5 O 15 at 950 °C in molten Na 2 SO 4 we observe the progression of numerous metastable phases. Using sequential multiphase Rietveld refinement of the time-dependent in situ XRD data, we are able to obtain mechanistic understanding of this reaction under a range of conditions.

Process Stability of Ultrasonic-Wave-Assisted Gas Metal Arc Welding

NASA Astrophysics Data System (ADS)

Fan, Chenglei; Xie, Weifeng; Yang, Chunli; Lin, Sanbao; Fan, Yangyang

2017-10-01

As a newly developed arc welding method, ultrasonic-wave-assisted arc welding successfully introduced power ultrasound into the arc and weld pool, during which the ultrasonic acts on the top of the arc in the coaxial alignment direction. The advanced process for molten metals can be realized by using an additional ultrasonic field. Compared with the conventional gas metal arc welding (GMAW), the welding arc is compressed, the droplet size is decreased, and the droplet transfer frequency is increased significantly in ultrasonic-wave-assisted GMAW (U-GMAW). However, the stability of the metal transfer has deep influence on the welding quality equally, and the ultrasonic wave effect on the stability of the metal transfer is a phenomenon that is not completely understood. In this article, the stabilities of the short-circuiting transfer process and globular transfer process are studied systematically, and the effect of ultrasonic wave on the metal transfer is analyzed further. The transfer frequency and process stability of the U-GMAW process are much higher than those of the conventional GMAW. Analytical results show that the additional ultrasonic wave is helpful for improving welding stability.

Apparatus and method for stripping tritium from molten salt

DOE Office of Scientific and Technical Information (OSTI.GOV)

Holcomb, David E.; Wilson, Dane F.

A method of stripping tritium from flowing stream of molten salt includes providing a tritium-separating membrane structure having a porous support, a nanoporous structural metal-ion diffusion barrier layer, and a gas-tight, nonporous palladium-bearing separative layer, directing the flowing stream of molten salt into contact with the palladium-bearing layer so that tritium contained within the molten salt is transported through the tritium-separating membrane structure, and contacting a sweep gas with the porous support for collecting the tritium.

Method of preparing a sintered lithium aluminate structure for containing electrolyte

DOEpatents

Sim, James W.; Kinoshita, Kimio

1981-01-01

A porous sintered tile is formed of lithium aluminate for retaining molten lectrolyte within a fuel cell. The tile is prepared by reacting lithium hydroxide in aqueous solution with alumina particles to form beta lithium aluminate particles. The slurry is evaporated to dryness and the solids dehydrated to form a beta lithium aluminate powder. The powder is compacted into the desired shape and sintered at a temperature in excess of 1200 K. but less than 1900 K. to form a porous integral structure that is subsequently filled with molten electrolyte. A tile of this type is intended for use in containing molten alkali metal carbonates as electolyte for use in a fuel cell having porous metal or metal oxide electrodes for burning a fuel gas such as hydrogen and/or carbon monoxide with an oxidant gas containing oxygen.

Production of Oxygen from Lunar Regolith using Molten Oxide Electrolysis

NASA Technical Reports Server (NTRS)

Sibille, Laurent; Sadoway, Donald R.; Sirk, Aislinn; Tripathy, Prabhat; Melendez, Orlando; Standish, Evan; Dominquez, Jesus A.; Stefanescu, Doru M.; Curreri, Peter A.; Poizeau, Sophie

2009-01-01

This slide presentation reviews the possible use of molten oxide electrolysis to extract oxygen from the Lunar Regolith. The presentation asserts that molten regolith electrolysis has advanced to be a useful method for production of oxygen and metals in situ on the Moon. The work has demonstrated an 8 hour batch of electrolysis at 5 amps using Iridium inert anodes.

Process for the encapsulation and stabilization of radioactive, hazardous and mixed wastes

DOEpatents

Colombo, Peter; Kalb, Paul D.; Heiser, III, John H.

1997-11-14

The present invention provides a method for encapsulating and stabilizing radioactive, hazardous and mixed wastes in a modified sulfur cement composition. The waste may be incinerator fly ash or bottom ash including radioactive contaminants, toxic metal salts and other wastes commonly found in refuse. The process may use glass fibers mixed into the composition to improve the tensile strength and a low concentration of anhydrous sodium sulfide to reduce toxic metal solubility. The present invention preferably includes a method for encapsulating radioactive, hazardous and mixed wastes by combining substantially anhydrous wastes, molten modified sulfur cement, preferably glass fibers, as well as anhydrous sodium sulfide or calcium hydroxide or sodium hydroxide in a heated double-planetary orbital mixer. The modified sulfur cement is preheated to about 135.degree..+-.5.degree. C., then the remaining substantially dry components are added and mixed to homogeneity. The homogeneous molten mixture is poured or extruded into a suitable mold. The mold is allowed to cool, while the mixture hardens, thereby immobilizing and encapsulating the contaminants present in the ash.

Deployment of quasi-digital sensor for high temperature molten salt level measurement in pyroprocessing plants.

PubMed

Sanga, Ramesh; Agarwal, Sourabh; Sivaramakrishna, M; Rao, G Prabhakara

2018-04-01

Development of a liquid molten salt level sensor device that can detect the level of liquid molten salt in the process vessels of pyrochemical reprocessing of spent metallic fuels is detailed. It is proposed to apply a resistive-type pulsating sensor-based level measurement approach. There are no commercially available sensors due to limitations of high temperature, radiation, and physical dimensions. A compact, simple, rugged, low power, and high precise pulsating sensor-based level probe and simple instrumentation for the molten salt liquid level sensor to work in the extreme conditions has been indigenously developed, with high precision and accuracy. The working principle, design concept, and results have been discussed. This level probe is mainly composed of the variable resistor made up of ceramic rods. This resistor constitutes the part of resistance-capacitance-type Logic Gate Oscillator (LGO). A change in the molten salt level inside the tank causes a small change in the resistance which in turn changes the pulse frequency of the LGO. Thus the frequency, the output of the instrument that is displayed on the LCD of an embedded system, is a function of molten salt level. In the present design, the range of level measurement is about 10 mm. The sensitivity in position measurement up to 10 mm is ∼2.5 kHz/mm.

Deployment of quasi-digital sensor for high temperature molten salt level measurement in pyroprocessing plants

NASA Astrophysics Data System (ADS)

Sanga, Ramesh; Agarwal, Sourabh; Sivaramakrishna, M.; Rao, G. Prabhakara

2018-04-01

Development of a liquid molten salt level sensor device that can detect the level of liquid molten salt in the process vessels of pyrochemical reprocessing of spent metallic fuels is detailed. It is proposed to apply a resistive-type pulsating sensor-based level measurement approach. There are no commercially available sensors due to limitations of high temperature, radiation, and physical dimensions. A compact, simple, rugged, low power, and high precise pulsating sensor-based level probe and simple instrumentation for the molten salt liquid level sensor to work in the extreme conditions has been indigenously developed, with high precision and accuracy. The working principle, design concept, and results have been discussed. This level probe is mainly composed of the variable resistor made up of ceramic rods. This resistor constitutes the part of resistance-capacitance-type Logic Gate Oscillator (LGO). A change in the molten salt level inside the tank causes a small change in the resistance which in turn changes the pulse frequency of the LGO. Thus the frequency, the output of the instrument that is displayed on the LCD of an embedded system, is a function of molten salt level. In the present design, the range of level measurement is about 10 mm. The sensitivity in position measurement up to 10 mm is ˜2.5 kHz/mm.

Study on slag forming mechanism of hot metal containing titanium in converter

NASA Astrophysics Data System (ADS)

Wang, H. B.; Lv, Y. C.; Qin, L. Y.; Liu, Y.; Ma, C. W.; Kong, X. T.

2017-09-01

The use of titanium containing molten iron can expand the sources of raw materials, reduce the cost, but the process produce serious foaming slag, low dephosphorization proportion and the consumption of lime is high. The technicians have improved the operation process through experiments and solved the problem of efficient and smooth blowing of hot metal containing titanium. Through mine phase composition analysis of slag using SEM and EDS, the distribution of titanium and the regularity of phosphorus retention are found, and measures to prevent phosphorus recovery in the later stage of converter are put forward.

A dynamic inert metal anode.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hryn, J. N.

1998-11-09

A new concept for a stable anode for aluminum electrowinning is described. The anode consists of a cup-shaped metal alloy container filled with a molten salt that contains dissolved aluminum. The metal alloy can be any of a number of alloys, but it must contain aluminum as a secondary alloying metal. A possible alloy composition is copper with 5 to 15 weight percent aluminum. In the presence of oxygen, aluminum on the metal anode's exterior surface forms a continuous alumina film that is thick enough to protect the anode from chemical attack by cryolite during electrolysis and thin enough tomore » maintain electrical conductivity. However, the alumina film is soluble in cryolite, so it must be regenerated in situ. Film regeneration is achieved by the transport of aluminum metal from the anode's molten salt interior through the metal wall to the anode's exterior surface, where the transported aluminum oxidizes to alumina in the presence of evolving oxygen to maintain the protective alumina film. Periodic addition of aluminum metal to the anode's interior keeps the aluminum activity in the molten salt at the desired level. This concept for an inert anode is viable as long as the amount of aluminum produced at the cathode greatly exceeds the amount of aluminum required to maintain the anode's protective film.« less

Polarization and mass transfer during the electrolysis of molten salts with liquid metallic electrodes

NASA Astrophysics Data System (ADS)

Mikhalev, Yu. G.

2014-08-01

Calculations are used to show that the fraction of the overvoltage of the stage of discharge-ionization can be significant in the total overvoltage during the polarization of liquid metallic electrodes in molten chlorides depleted of electrochemically active particles (depending on the type of the dissipative structures that appear near the electrode/electrolyte interface). This finding is taken into account to obtain criterion equations to describe the mass-transfer rate as a function of the physicochemical properties of the electrolyte and the metal electrode.

Optical Properties of Silver Nanoparticulate Glasses

NASA Astrophysics Data System (ADS)

Evans, Rachel N.; Cannavino, Sarah A.; King, Christy A.; Lamartina, Joseph A.; Magruder, Robert H.; Ferrara, Davon W.

The ion exchange method of embedding metal nanoparticles (NPs) into float glass is an often used technique of fabricating colored glasses and graded-index waveguides. The depth and size of NP formation in the glass depends on the concentration and temperature of metal ions in the molten bath. In this study we explore the dichroic properties of silver metal ion exchange restricted to only one side of a glass microscope slide using reflection and transmission spectroscopy and its dependence on temperature, concentration of silver ions, and length of time in the molten bath.

All ceramic structure for molten carbonate fuel cell

DOEpatents

Smith, James L.; Kucera, Eugenia H.

1992-01-01

An all-ceramic molten carbonate fuel cell having a composition formed of a multivalent metal oxide or oxygenate such as an alkali metal, transition metal oxygenate. The structure includes an anode and cathode separated by an electronically conductive interconnect. The electrodes and interconnect are compositions ceramic materials. Various combinations of ceramic compositions for the anode, cathode and interconnect are disclosed. The fuel cell exhibits stability in the fuel gas and oxidizing environments. It presents reduced sealing and expansion problems in fabrication and has improved long-term corrosion resistance.

The use of Ni-Cr-Si-Be filler metals for brazing of stainless steels

NASA Astrophysics Data System (ADS)

Ivannikov, A.; Fedotov, V.; Suchkov, A.; Penyaz, M.; Fedotov, I.; Tarasov, B.

2016-04-01

Nanocrystalline ribbon filler metal-alloys of system Ni-Cr-Si-Be are produced by the rapidly quenching of the melt method. By these filler metals carried out hight temperature vacuum brazing of austenitic steels (12Kh18N10T and Kh18N8G2) and austenitic-ferritic class EI-811 (12Kh21N5T). The basic laws of structure-phase state foundation of brazed joints are determined, features of the interaction of the molten filler metal to the brazed materials are identified, the optimal temperature and time parameters of the brazing process are determined.

Gas Atomization of Molten Metal: Part II. Applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Abu-Lebdeh, Taher M.; Leon, Genaro Perez-de; Hamoush, Sameer A.

A numerical model was derived to obtain results for two alloys during the Gas Atomization (GA) method. The model equations and governing equations were implemented through the application of part I data. Aspects such as heat transfer, fluid mechanics, thermodynamics and law of motions were taken into account for the formulation of equations that take gas dynamics, droplet dynamics and energy balance or conservation into consideration. The inputs of the model include: Processing parameters such as the size of the droplets, characteristics of the metal alloy, initial temperature of the molten metal, properties and fractions of the atomization gas andmore » the gas pressure. The outputs include velocity and thermal profiles of the droplet and gas. Velocity profiles illustrate the velocity of both droplet and gas, while thermal profiles illustrate cooling rate and the rate of temperature change of the droplets. The alloys are gamma-Titanium Aluminide (γ-TiAl) and Al-3003-O. These alloys were selected due to the vast amount of applications both can have in several industries. Certain processing parameters were held constant, while others were altered. Furthermore, the main focus of this study was to gain insight into which optimal parameters should be utilized within the GA method for these alloys and to provide insight into the behavior of these alloys« less

Gas Atomization of Molten Metal: Part II. Applications

DOE PAGES

Abu-Lebdeh, Taher M.; Leon, Genaro Perez-de; Hamoush, Sameer A.; ...

2016-02-01

A numerical model was derived to obtain results for two alloys during the Gas Atomization (GA) method. The model equations and governing equations were implemented through the application of part I data. Aspects such as heat transfer, fluid mechanics, thermodynamics and law of motions were taken into account for the formulation of equations that take gas dynamics, droplet dynamics and energy balance or conservation into consideration. The inputs of the model include: Processing parameters such as the size of the droplets, characteristics of the metal alloy, initial temperature of the molten metal, properties and fractions of the atomization gas andmore » the gas pressure. The outputs include velocity and thermal profiles of the droplet and gas. Velocity profiles illustrate the velocity of both droplet and gas, while thermal profiles illustrate cooling rate and the rate of temperature change of the droplets. The alloys are gamma-Titanium Aluminide (γ-TiAl) and Al-3003-O. These alloys were selected due to the vast amount of applications both can have in several industries. Certain processing parameters were held constant, while others were altered. Furthermore, the main focus of this study was to gain insight into which optimal parameters should be utilized within the GA method for these alloys and to provide insight into the behavior of these alloys« less

A novel molten-salt electrochemical cell for investigating the reduction of uranium dioxide to uranium metal by lithium using in situ synchrotron radiation

PubMed Central

Brown, Leon D.; Abdulaziz, Rema; Jervis, Rhodri; Bharath, Vidal; Mason, Thomas J.; Reinhard, Christina; Connor, Leigh D.; Inman, Douglas; Brett, Daniel J. L.; Shearing, Paul R.

2017-01-01

A novel electrochemical cell has been designed and built to allow for in situ energy-dispersive X-ray diffraction measurements to be made during reduction of UO2 to U metal in LiCl–KCl at 500°C. The electrochemical cell contains a recessed well at the bottom of the cell into which the working electrode sits, reducing the beam path for the X-rays through the molten-salt and maximizing the signal-to-noise ratio from the sample. Lithium metal was electrodeposited onto the UO2 working electrode by exposing the working electrode to more negative potentials than the Li deposition potential of the LiCl–KCl eutectic electrolyte. The Li metal acts as a reducing agent for the chemical reduction of UO2 to U, which appears to proceed to completion. All phases were fitted using Le Bail refinement. The cell is expected to be widely applicable to many studies involving molten-salt systems. PMID:28244437

A novel molten-salt electrochemical cell for investigating the reduction of uranium dioxide to uranium metal by lithium using in situ synchrotron radiation.

PubMed

Brown, Leon D; Abdulaziz, Rema; Jervis, Rhodri; Bharath, Vidal; Mason, Thomas J; Atwood, Robert C; Reinhard, Christina; Connor, Leigh D; Inman, Douglas; Brett, Daniel J L; Shearing, Paul R

2017-03-01

A novel electrochemical cell has been designed and built to allow for in situ energy-dispersive X-ray diffraction measurements to be made during reduction of UO 2 to U metal in LiCl-KCl at 500°C. The electrochemical cell contains a recessed well at the bottom of the cell into which the working electrode sits, reducing the beam path for the X-rays through the molten-salt and maximizing the signal-to-noise ratio from the sample. Lithium metal was electrodeposited onto the UO 2 working electrode by exposing the working electrode to more negative potentials than the Li deposition potential of the LiCl-KCl eutectic electrolyte. The Li metal acts as a reducing agent for the chemical reduction of UO 2 to U, which appears to proceed to completion. All phases were fitted using Le Bail refinement. The cell is expected to be widely applicable to many studies involving molten-salt systems.

Energy Consumption of Die Casting Operations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jerald Brevick; clark Mount-Campbell; Carroll Mobley

2004-03-15

Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption [1]. The obvious major energy requirements are for melting and holding molten alloy in preparation for casting. The proper selection and maintenance of melting and holding equipment are clearly important factors in minimizing energy consumption in die-casting operations [2]. In addition to energy consumption, furnace selection also influences metal loss due to oxidation, metal quality, and maintenance requirements. Other important factors influencing energy consumption in a die-casting facility include geographic location, alloy(s) cast, starting formmore » of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting machine, related equipment (robots, trim presses), and downstream processing (machining, plating, assembly, etc.). Each of these factors also may influence the casting quality and productivity of a die-casting enterprise. In a die-casting enterprise, decisions regarding these issues are made frequently and are based on a large number of factors. Therefore, it is not surprising that energy consumption can vary significantly from one die-casting enterprise to the next, and within a single enterprise as function of time.« less

Simulation of the Continuous Casting and Cooling Behavior of Metallic Glasses

PubMed Central

Pei, Zhipu; Ju, Dongying

2017-01-01

The development of melt spinning technique for preparation of metallic glasses was summarized. The limitations as well as restrictions of the melt spinning embodiments were also analyzed. As an improvement and variation of the melt spinning method, the vertical-type twin-roll casting (VTRC) process was discussed. As the thermal history experienced by the casting metals to a great extent determines the qualities of final products, cooling rate in the quenching process is believed to have a significant effect on glass formation. In order to estimate the ability to produce metallic glasses by VTRC method, temperature and flow phenomena of the melt in molten pool were computed, and cooling rates under different casting conditions were calculated with the simulation results. Considering the fluid character during casting process, the material derivative method based on continuum theory was adopted in the cooling rate calculation. Results show that the VTRC process has a good ability in continuous casting metallic glassy ribbons. PMID:28772779

Simulation of the Continuous Casting and Cooling Behavior of Metallic Glasses.

PubMed

Pei, Zhipu; Ju, Dongying

2017-04-17

The development of melt spinning technique for preparation of metallic glasses was summarized. The limitations as well as restrictions of the melt spinning embodiments were also analyzed. As an improvement and variation of the melt spinning method, the vertical-type twin-roll casting (VTRC) process was discussed. As the thermal history experienced by the casting metals to a great extent determines the qualities of final products, cooling rate in the quenching process is believed to have a significant effect on glass formation. In order to estimate the ability to produce metallic glasses by VTRC method, temperature and flow phenomena of the melt in molten pool were computed, and cooling rates under different casting conditions were calculated with the simulation results. Considering the fluid character during casting process, the material derivative method based on continuum theory was adopted in the cooling rate calculation. Results show that the VTRC process has a good ability in continuous casting metallic glassy ribbons.

Separation of Zirconium and Hafnium: A Review

NASA Astrophysics Data System (ADS)

Xu, L.; Xiao, Y.; van Sandwijk, A.; Xu, Q.; Yang, Y.

Zirconium is an ideal material for nuclear reactors due to its low absorption cross-section for thermal neutrons, whereas the typically contained hafnium with strong neutron-absorption is very harmful for zirconium. This paper provides an overview of the processes for separating hafnium from zirconium. The separation processes are roughly classified into hydro- and pyrometallurgical routes. The current dominant zirconium production route involves pyrometallurgical ore cracking, multi-step hydrometallurgical liquid-liquid extraction for hafnium removal and the reduction of zirconium tetrachloride to the pure metal by the Kroll process. The lengthy hydrometallurgical Zr-Hf separation operations leads to high production cost, intensive labour and heavy environmental burden. Using a compact pyrometallurgical separation method can simplify the whole production flowsheet with a higher process efficiency. The known separation methods are discussed based on the following reaction features: redox characteristics, volatility, electrochemical properties and molten salt extraction. The commercially operating extractive distillation process is a significant advance in Zr-Hf separation technology but it suffers from high process maintenance cost. The recently developed new process based on molten salt-metal equilibrium for Zr-Hf separation shows a great potential for industrial application, which is compact for nuclear grade zirconium production starting from crude ore. In the present paper, the available separation technologies are compared. The advantages and disadvantages as well as future directions of research and development for nuclear grade zirconium production are discussed.

Molten salt extraction of transuranic and reactive fission products from used uranium oxide fuel

DOEpatents

Herrmann, Steven Douglas

2014-05-27

Used uranium oxide fuel is detoxified by extracting transuranic and reactive fission products into molten salt. By contacting declad and crushed used uranium oxide fuel with a molten halide salt containing a minor fraction of the respective uranium trihalide, transuranic and reactive fission products partition from the fuel to the molten salt phase, while uranium oxide and non-reactive, or noble metal, fission products remain in an insoluble solid phase. The salt is then separated from the fuel via draining and distillation. By this method, the bulk of the decay heat, fission poisoning capacity, and radiotoxicity are removed from the used fuel. The remaining radioactivity from the noble metal fission products in the detoxified fuel is primarily limited to soft beta emitters. The extracted transuranic and reactive fission products are amenable to existing technologies for group uranium/transuranic product recovery and fission product immobilization in engineered waste forms.

Electrochemical properties of a lithium-impregnated metal foam anode for thermal batteries

NASA Astrophysics Data System (ADS)

Choi, Yu-Song; Yu, Hye-Ryeon; Cheong, Hae-Won

2015-02-01

Lithium-impregnated metal foam anodes (LIMFAs) are fabricated and investigated. The LIMFAs are prepared by the impregnation of lithium into molten-salt-coated nickel metal foam. A single cell with the LIMFA exhibits a specific capacity of 3009 As g-1. For comparison, a single cell with a LiSi alloy anode is also discharged, demonstrating a specific capacity of 1050 As g-1. These significant improvements can be attributed to the large amount of lithium impregnated into the metal foam as well as the molten lithium holding capability of the foam. Due to their excellent electrochemical properties, LIMFAs are suitable for use in thermal batteries.

Molten Boron Phase-Change Thermal Energy Storage to Augment Solar Thermal Propulsion Systems

DTIC Science & Technology

2011-07-13

Thermodynamic Properties of Transition Metal Borides . I. The Molybdenum-boron system and Elemental Boron," Journal of Physical Chemistry, Vol. 81...February 1977, pp. 318-324. 38Itoh, H., Matsudaira, T., and Naka, S., "Formation Process of Tungsten Borides by Solid State Reaction Between Tungsten...Molybdenum-Boron and Some Properties of The Molybdenum- Borides ," Journal of Metals, September 1952, pp. 983-988. 40Stout, N. D., Mar, R. W., and Boo, W. O

Spray forming process for producing molds, dies and related tooling

DOEpatents

McHugh, Kevin M.; Key, James F.

1998-01-01

A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.

Spray forming process for producing molds, dies and related tooling

DOEpatents

McHugh, K.M.; Key, J.F.

1998-02-17

A method is disclosed for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers. 17 figs.

Processing and properties of magnesium containing a dense uniform dispersion of nanoparticles.

PubMed

Chen, Lian-Yi; Xu, Jia-Quan; Choi, Hongseok; Pozuelo, Marta; Ma, Xiaolong; Bhowmick, Sanjit; Yang, Jenn-Ming; Mathaudhu, Suveen; Li, Xiao-Chun

2015-12-24

Magnesium is a light metal, with a density two-thirds that of aluminium, is abundant on Earth and is biocompatible; it thus has the potential to improve energy efficiency and system performance in aerospace, automobile, defence, mobile electronics and biomedical applications. However, conventional synthesis and processing methods (alloying and thermomechanical processing) have reached certain limits in further improving the properties of magnesium and other metals. Ceramic particles have been introduced into metal matrices to improve the strength of the metals, but unfortunately, ceramic microparticles severely degrade the plasticity and machinability of metals, and nanoparticles, although they have the potential to improve strength while maintaining or even improving the plasticity of metals, are difficult to disperse uniformly in metal matrices. Here we show that a dense uniform dispersion of silicon carbide nanoparticles (14 per cent by volume) in magnesium can be achieved through a nanoparticle self-stabilization mechanism in molten metal. An enhancement of strength, stiffness, plasticity and high-temperature stability is simultaneously achieved, delivering a higher specific yield strength and higher specific modulus than almost all structural metals.

Study on Surface Depression of Ti-6Al-4V with Ultrahigh-Frequency Pulsed Gas Tungsten Arc Welding

NASA Astrophysics Data System (ADS)

Mingxuan, Yang; Zhou, Yang; Bojin, Qi

2015-08-01

Molten pool surface depression was observed with the arc welding process that was caused by arc pressure. It was supposed to have a significant effect on fluid in the molten pool that was important for the microstructure and joint properties. The impact of arc force was recognized as the reason for the surface depression during arc welding. The mathematical distribution of arc force was produced with the exponent and parabola models. Different models showed different concentrations and attenuations. The comparison between them was discussed with the simulation results. The volume of fluid method was picked up with the arc force distribution model. The surface depression was caused by the arc force. The geometry of the surface depression was discussed with liquid metal properties. The welding process was carried out with different pulsed frequencies. The results indicated the forced depression exists in molten pool and the geometry of depression was hugely due to the arc force distribution. The previous work calculated the depression in the center with force balance at one point. The other area of gas shielding was resistant by the reverse gravity from the feedback of liquid metal that was squeezed out. The article discusses the pressure effect with free deformation that allowed resistance of liquid and was easy to compare with different distributions. The curve profiles were studied with the arc force distributions, and exponent model was supposed to be more accurate to the as-weld condition.

Wire Composition: Its Effect on Metal Disintegration and Particle Formation in Twin-Wire Arc-Spraying Process

NASA Astrophysics Data System (ADS)

Tillmann, W.; Abdulgader, M.

2013-03-01

The wire tips in twin-wire arc-spraying (TWAS) are heated in three different zones. A high-speed camera was used to observe the melting behavior, metal breakup, and particle formation under different operating conditions. In zone (I), the wire tips are melted (liquidus metal) and directly atomized in the form of smaller droplets. Their size is a function of the specific properties of the molten metal and the exerting aerodynamic forces. Zone (II) is directly beneath zone (I) and the origin of the extruded metal sheets at the wire tips. The extruded metal sheets in the case of cored wires are shorter than those observed while using solid wires. In this study, the effects of adjustable parameters and powder filling on melting behavior, particle formation, and process instability were revealed, and a comparison between solid and cored wires was made. The findings can improve the accuracy of the TWAS process modeling.

Time-dependent calculations of molten pool formation and thermal plasma with metal vapour in gas tungsten arc welding

NASA Astrophysics Data System (ADS)

Tanaka, M.; Yamamoto, K.; Tashiro, S.; Nakata, K.; Yamamoto, E.; Yamazaki, K.; Suzuki, K.; Murphy, A. B.; Lowke, J. J.

2010-11-01

A gas tungsten arc (GTA) was modelled taking into account the contamination of the plasma by metal vapour from the molten anode. The whole region of GTA atmosphere including the tungsten cathode, the arc plasma and the anode was treated using a unified numerical model. A viscosity approximation was used to express the diffusion coefficient in terms of viscosity of the shielding gas and metal vapour. The transient two-dimensional distributions of temperature, velocity of plasma flow and iron vapour concentration were predicted, together with the molten pool as a function of time for a 150 A arc current at atmospheric pressure, both for helium and argon gases. It was shown that the thermal plasma in the GTA was influenced by iron vapour from the molten pool surface and that the concentration of iron vapour in the plasma was dependent on the temperature of the molten pool. GTA on high sulfur stainless steel was calculated to discuss the differences between a low sulfur and a high sulfur stainless steel anode. Helium was selected as the shielding gas because a helium GTA produces more metal vapour than an argon GTA. In the GTA on a high sulfur stainless steel anode, iron vapour and current path were constricted. Radiative emission density in the GTA on high sulfur stainless steel was also concentrated in the centre area of the arc plasma together with the iron vapour although the temperature distributions were almost the same as that in the case of a low sulfur stainless steel anode.

Ab-Initio Molecular Dynamics Simulations of Molten Ni-Based Superalloys (Preprint)

DTIC Science & Technology

2011-10-01

in liquid–metal density with composition and temperature across the solidification zone. Here, fundamental properties of molten Ni -based alloys ...temperature across the solidification zone. Here, fundamental properties of molten Ni -based alloys , required for modeling these instabilities, are...temperature is assessed in model Ni -Al-W and RENE-N4 alloys . Calculations are performed using a recently implemented constant pressure methodology (NPT) which

An Overview of the MSFC Electrostatic Levitation Facility

NASA Technical Reports Server (NTRS)

Rogers, J. R.; Robinson, M. B.; Hyers, R. W.; Savage, L.; Rathz, T.

2000-01-01

Electrostatic levitation (ESL) provides a means to study molten materials in a contamination-free environment, including no contact with a container. Many phenomena important to materials science can be studied in the ESL. Solidification of metals, alloys and undercooled materials represent an important topic for research in the ESL. Recent studies of metals and alloys during solidification in the ESL are reported. Measurements include time, temperature and transformation of metallic glass-forming alloys, solidification velocities, and microstructure. This multimedia report includes a video clip showing processing in the ESL, with descriptions of the different segments in the text.

Induction slag reduction process for purifying metals

DOEpatents

Traut, Davis E.; Fisher, II, George T.; Hansen, Dennis A.

1991-01-01

A continuous method is provided for purifying and recovering transition metals such as neodymium and zirconium that become reactive at temperatures above about 500.degree. C. that comprises the steps of contacting the metal ore with an appropriate fluorinating agent such as an alkaline earth metal fluosilicate to form a fluometallic compound, and reducing the fluometallic compound with a suitable alkaline earth or alkali metal compound under molten conditions, such as provided in an induction slag metal furnace. The method of the invention is advantageous in that it is simpler and less expensive than methods used previously to recover pure metals, and it may be employed with a wide range of transition metals that were reactive with enclosures used in the prior art methods and were hard to obtain in uncontaminated form.

Zirconium behaviour during electrorefining of actinide-zirconium alloy in molten LiCl-KCl on aluminium cathodes

NASA Astrophysics Data System (ADS)

Meier, R.; Souček, P.; Malmbeck, R.; Krachler, M.; Rodrigues, A.; Claux, B.; Glatz, J.-P.; Fanghänel, Th.

2016-04-01

A pyrochemical electrorefining process for the recovery of actinides from metallic nuclear fuel based on actinide-zirconium alloys (An-Zr) in a molten salt is being investigated. In this process actinides are group-selectively recovered on solid aluminium cathodes as An-Al alloys using a LiCl-KCl eutectic melt at a temperature of 450 °C. In the present study the electrochemical behaviour of zirconium during electrorefining was investigated. The maximum amount of actinides that can be oxidised without anodic co-dissolution of zirconium was determined at a selected constant cathodic current density. The experiment consisted of three steps to assess the different stages of the electrorefining process, each of which employing a fresh aluminium cathode. The results indicate that almost a complete dissolution of the actinides without co-dissolution of zirconium is possible under the applied experimental conditions.

Chemical Reduction of SIM MOX in Molten Lithium Chloride Using Lithium Metal Reductant

NASA Astrophysics Data System (ADS)

Kato, Tetsuya; Usami, Tsuyoshi; Kurata, Masaki; Inoue, Tadashi; Sims, Howard E.; Jenkins, Jan A.

2007-09-01

A simulated spent oxide fuel in a sintered pellet form, which contained the twelve elements U, Pu, Am, Np, Cm, Ce, Nd, Sm, Ba, Zr,Mo, and Pd, was reduced with Li metal in a molten LiCl bath at 923 K. More than 90% of U and Pu were reduced to metal to form a porous alloy without significant change in the Pu/U ratio. Small fractions of Pu were also combined with Pd to form stable alloys. In the gap of the porous U-Pu alloy, the aggregation of the rare-earth (RE) oxide was observed. Some amount of the RE elements and the actinoides leached from the pellet. The leaching ratio of Am to the initially loaded amount was only several percent, which was far from about 80% obtained in the previous ones on simple MOX including U, Pu, and Am. The difference suggests that a large part of Am existed in the RE oxide rather than in the U-Pu alloy. The detection of the RE elements and actinoides in the molten LiCl bath seemed to indicate that they dissolved into the molten LiCl bath containing the oxide ion, which is the by-product of the reduction, as solubility of RE elements was measured in the molten LiCl-Li2O previously.

[Bio-oil production from biomass pyrolysis in molten salt].

PubMed

Ji, Dengxiang; Cai, Tengyue; Ai, Ning; Yu, Fengwen; Jiang, Hongtao; Ji, Jianbing

2011-03-01

In order to investigate the effects of pyrolysis conditions on bio-oil production from biomass in molten salt, experiments of biomass pyrolysis were carried out in a self-designed reactor in which the molten salt ZnCl2-KCl (with mole ratio 7/6) was selected as heat carrier, catalyst and dispersion agent. The effects of metal salt added into ZnCl2-KCl and biomass material on biomass pyrolysis were discussed, and the main compositions of bio-oil were determined by GC-MS. Metal salt added into molten salt could affect pyrolysis production yields remarkably. Lanthanon salt could enhance bio-oil yield and decrease water content in bio-oil, when mole fraction of 5.0% LaCl3 was added, bio-oil yield could reach up to 32.0%, and water content of bio-oil could reduce to 61.5%. The bio-oil and char yields were higher when rice straw was pyrolysed, while gas yield was higher when rice husk was used. Metal salts showed great selectivity on compositions of bio-oil. LiCl and FeCl2 promoted biomass to pyrolyse into smaller molecular weight compounds. CrCl3, CaCl2 and LaCl3 could restrain second pyrolysis of bio-oil. The research provided a scientific reference for production of bio-oil from biomass pyrolysis in molten salt.

Azimuthal swirl in liquid metal electrodes and batteries

NASA Astrophysics Data System (ADS)

Ashour, Rakan; Kelley, Douglas

2016-11-01

Liquid metal batteries consist of two molten metals with different electronegativity separated by molten salt. In these batteries, critical performance related factors such as the limiting current density are governed by fluid mixing in the positive electrode. In this work we present experimental results of a swirling flow in a layer of molten lead-bismuth alloy driven by electrical current. Using in-situ ultrasound velocimetery, we show that poloidal circulation appears at low current density, whereas azimuthal swirl becomes dominant at higher current density. The presence of thermal gradients produces buoyant forces, which are found to compete with those produced by current injection. Taking the ratio of the characteristic electromagnetic to buoyant flow velocity, we are able to predict the current density at which the flow becomes electromagnetically driven. Scaling arguments are also used to show that swirl is generated through self-interaction between the electrical current in the electrode with its own magnetic field.

Chemical interactions and thermodynamic studies in aluminum alloy/molten salt systems

NASA Astrophysics Data System (ADS)

Narayanan, Ramesh

The recycling of aluminum and aluminum alloys such as Used Beverage Container (UBC) is done under a cover of molten salt flux based on (NaCl-KCl+fluorides). The reactions of aluminum alloys with molten salt fluxes have been investigated. Thermodynamic calculations are performed in the alloy/salt flux systems which allow quantitative predictions of the equilibrium compositions. There is preferential reaction of Mg in Al-Mg alloy with molten salt fluxes, especially those containing fluorides like NaF. An exchange reaction between Al-Mg alloy and molten salt flux has been demonstrated. Mg from the Al-Mg alloy transfers into the salt flux while Na from the salt flux transfers into the metal. Thermodynamic calculations indicated that the amount of Na in metal increases as the Mg content in alloy and/or NaF content in the reacting flux increases. This is an important point because small amounts of Na have a detrimental effect on the mechanical properties of the Al-Mg alloy. The reactions of Al alloys with molten salt fluxes result in the formation of bluish purple colored "streamers". It was established that the streamer is liquid alkali metal (Na and K in the case of NaCl-KCl-NaF systems) dissipating into the melt. The melts in which such streamers were observed are identified. The metal losses occurring due to reactions have been quantified, both by thermodynamic calculations and experimentally. A computer program has been developed to calculate ternary phase diagrams in molten salt systems from the constituting binary phase diagrams, based on a regular solution model. The extent of deviation of the binary systems from regular solution has been quantified. The systems investigated in which good agreement was found between the calculated and experimental phase diagrams included NaF-KF-LiF, NaCl-NaF-NaI and KNOsb3-TINOsb3-LiNOsb3. Furthermore, an insight has been provided on the interrelationship between the regular solution parameters and the topology of the phase diagram. The isotherms are flat (i.e. no skewness) when the regular solution parameters are zero. When the regular solution parameters are non-zero, the isotherms are skewed. A regular solution model is not adequate to accurately model the molten salt systems used in recycling like NaCl-KCl-LiF and NaCl-KCl-NaF.

Separation of actinides from irradiated An-Zr based fuel by electrorefining on solid aluminium cathodes in molten LiCl-KCl

NASA Astrophysics Data System (ADS)

Souček, P.; Murakami, T.; Claux, B.; Meier, R.; Malmbeck, R.; Tsukada, T.; Glatz, J.-P.

2015-04-01

An electrorefining process for metallic spent nuclear fuel treatment is being investigated in ITU. Solid aluminium cathodes are used for homogeneous recovery of all actinides within the process carried out in molten LiCl-KCl eutectic salt at a temperature of 500 °C. As the selectivity, efficiency and performance of solid Al has been already shown using un-irradiated An-Zr alloy based test fuels, the present work was focused on laboratory-scale demonstration of the process using irradiated METAPHIX-1 fuel composed of U67-Pu19-Zr10-MA2-RE2 (wt.%, MA = Np, Am, Cm, RE = Nd, Ce, Gd, Y). Different electrorefining techniques, conditions and cathode geometries were used during the experiment yielding evaluation of separation factors, kinetic parameters of actinide-aluminium alloy formation, process efficiency and macro-structure characterisation of the deposits. The results confirmed an excellent separation and very high efficiency of the electrorefining process using solid Al cathodes.

Relaxation dynamics of femtosecond-laser-induced temperature modulation on the surfaces of metals and semiconductors

NASA Astrophysics Data System (ADS)

Levy, Yoann; Derrien, Thibault J.-Y.; Bulgakova, Nadezhda M.; Gurevich, Evgeny L.; Mocek, Tomáš

2016-06-01

Formation of laser-induced periodic surface structures (LIPSS) is a complicated phenomenon which involves periodic spatial modulation of laser energy absorption on the irradiated surface, transient changes in optical response, surface layer melting and/or ablation. The listed processes strongly depend on laser fluence and pulse duration as well as on material properties. This paper is aimed at studying the spatiotemporal evolution of a periodic modulation of the deposited laser energy, once formed upon irradiation of metal (Ti) and semiconductor (Si) surfaces. Assuming that the incoming laser pulse interferes with a surface electromagnetic wave, the resulting sinusoidal modulation of the absorbed laser energy is introduced into a two-dimensional two-temperature model developed for titanium and silicon. Simulations reveal that the lattice temperature modulation on the surfaces of both materials following from the modulated absorption remains significant for longer than 50 ps after the laser pulse. In the cases considered here, the partially molten phase exists 10 ps in Ti and more than 50 ps in Si, suggesting that molten matter can be subjected to temperature-driven relocation toward LIPSS formation, due to the modulated temperature profile on the material surfaces. Molten phase at nanometric distances (nano-melting) is also revealed.

Methods of forming steel

DOEpatents

Branagan, Daniel J.; Burch, Joseph V.

2001-01-01

In one aspect, the invention encompasses a method of forming a steel. A metallic glass is formed and at least a portion of the glass is converted to a crystalline steel material having a nanocrystalline scale grain size. In another aspect, the invention encompasses another method of forming a steel. A molten alloy is formed and cooled the alloy at a rate which forms a metallic glass. The metallic glass is devitrified to convert the glass to a crystalline steel material having a nanocrystalline scale grain size. In yet another aspect, the invention encompasses another method of forming a steel. A first metallic glass steel substrate is provided, and a molten alloy is formed over the first metallic glass steel substrate to heat and devitrify at least some of the underlying metallic glass of the substrate.

Natural Catalysts for Molten Cellulose Pyrolysis to Targeted Bio-Oils

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dauenhauer, Paul J.

2017-06-02

Catalysis of biomass biopolymer cellulose by alkaline earth metals is a fundamental chemistry relevant to energy processes including combustion, pyrolysis and gasification. In this work, the catalytic decomposition of cellulose by calcium ions was evaluated at high temperature (400-500°C) to elucidate the chemical mechanisms leading to the formation of volatile organic compounds.

METHOD FOR COATING GRAPHITE WITH METALLIC CARBIDES

DOEpatents

Steinberg, M.A.

1960-03-22

A method for producing refractory coatings of metallic carbides on graphite was developed. In particular, the graphite piece to be coated is immersed in a molten solution of 4 to 5% by weight of zirconium, titanium, or niobium dissolved in tin. The solution is heated in an argon atmosphere to above 1400 deg C, whereby the refractory metal reacts with the surface of the graphite to form a layer of metalic carbide. The molten solution is cooled to 300 to 400 deg C, and the graphite piece is removed. Excess tin is wiped from the graphite, which is then heated in vacuum to above 2300 deg C. The tin vaporizes from the graphite surface, leaving the surface coated with a tenacious layer of refractory metallic carbide.

Method for converting UF5 to UF4 in a molten fluoride salt

DOEpatents

Bennett, Melvin R.; Bamberger, Carlos E.; Kelmers, A. Donald

1977-01-01

The reduction of UF.sub.5 to UF.sub.4 in a molten fluoride salt by sparging with hydrogen is catalyzed by metallic platinum. The reaction is also catalyzed by platinum alloyed with gold reaction equipment.

Gasification of black liquor

DOEpatents

Kohl, A.L.

1987-07-28

A concentrated aqueous black liquor containing carbonaceous material and alkali metal sulfur compounds is treated in a gasifier vessel containing a relatively shallow molten salt pool at its bottom to form a combustible gas and a sulfide-rich melt. The gasifier vessel, which is preferably pressurized, has a black liquor drying zone at its upper part, a black liquor solids gasification zone located below the drying zone, and a molten salt sulfur reduction zone which comprises the molten salt pool. A first portion of an oxygen-containing gas is introduced into the gas space in the gasification zone immediately above the molten salt pool. The remainder of the oxygen-containing gas is introduced into the molten salt pool in an amount sufficient to cause gasification of carbonaceous material entering the pool from the gasification zone but not sufficient to create oxidizing conditions in the pool. The total amount of the oxygen-containing gas introduced both above the pool and into the pool constitutes between 25 and 55% of the amount required for complete combustion of the black liquor feed. A combustible gas is withdrawn from an upper portion of the drying zone, and a melt in which the sulfur content is predominantly in the form of alkali metal sulfide is withdrawn from the molten salt sulfur reduction zone. 2 figs.

Gasification of black liquor

DOEpatents

Kohl, Arthur L.

1987-07-28

A concentrated aqueous black liquor containing carbonaceous material and alkali metal sulfur compounds is treated in a gasifier vessel containing a relatively shallow molten salt pool at its bottom to form a combustible gas and a sulfide-rich melt. The gasifier vessel, which is preferably pressurized, has a black liquor drying zone at its upper part, a black liquor solids gasification zone located below the drying zone, and a molten salt sulfur reduction zone which comprises the molten salt pool. A first portion of an oxygen-containing gas is introduced into the gas space in the gasification zone immediatley above the molten salt pool. The remainder of the oxygen-containing gas is introduced into the molten salt pool in an amount sufficient to cause gasification of carbonaceous material entering the pool from the gasification zone but not sufficient to create oxidizing conditions in the pool. The total amount of the oxygen-containing gas introduced both above the pool and into the pool constitutes between 25 and 55% of the amount required for complete combustion of the black liquor feed. A combustible gas is withdrawn from an upper portion of the drying zone, and a melt in which the sulfur content is predominantly in the form of alkali metal sulfide is withdrawn from the molten salt sulfur reduction zone.

Electrochemical cell assembled in discharged state

DOEpatents

Yao, Neng-Ping; Walsh, William J.

1976-01-01

A secondary, electrochemical cell is assembled in a completely discharged state within a sealed containment. As assembled, the cell includes a positive electrode separated from a negative electrode by a molten salt electrolyte. The positive electrode is contained within a porous structure, permitting passage of molten electrolyte, and includes one or more layers of a metallic mesh, e.g. iron, impregnated with an intimate mixture of lithium sulfide and the electrolyte. The negative electrode is a porous plaque of aluminum metal. Prior to using the cell, an electrical charge forms lithium-aluminum alloy within the negative electrode and metal sulfide within the positive electrode.

Feasibility tests of nickel as a containment material of molten Li2O-LiCl salt containing Li metal at 650 °C during electrolytic reduction

NASA Astrophysics Data System (ADS)

Choi, Eun-Young; Lee, Jeong

2017-11-01

In this study, we investigated the feasibility of nickel (Ni) as a material to contain molten Li2O-LiCl salt containing lithium (Li) metal at 650 °C as an electrolyte during the electrolytic reduction process of pyroprocessing (also known as oxide reduction, OR). First, the behaviors of Ni in four different LiCl salts (0.1 wt% Li-LiCl, 1 and 8 wt% Li2O-LiCl, and 8 wt% Li2O-0.1 wt% Li-LiCl) in an argon atmosphere were examined through immersion tests. Then, Ni was used as a vessel material for five consecutive OR runs of simulated oxide fuel using 1.0 wt% Li2O-LiCl salt. The tested Ni was analyzed by microbalance, X-ray diffraction, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. Concentrations of Ni in the salt were measured using inductively coupled plasma atomic emission spectroscopy. No corrosion product of Ni, except Cr2Ni3, was observed on the Ni used for both the salt-immersion tests and the OR runs because the Ni was not exposed to oxygen gas. However, leaching of Ni in the OR salt containing excessive Li metal was observed. Therefore, Ni can be used as the salt containment material in the OR process when excessive Li metal and oxygen gas in the salt are maintained at low levels.

Direct LiT Electrolysis in a Metallic Fusion Blanket

DOE Office of Scientific and Technical Information (OSTI.GOV)

Olson, Luke

2016-09-30

A process that simplifies the extraction of tritium from molten lithium-based breeding blankets was developed. The process is based on the direct electrolysis of lithium tritide using a ceramic Li ion conductor that replaces the molten salt extraction step. Extraction of tritium in the form of lithium tritide in the blankets/targets of fusion/fission reactors is critical in order to maintain low concentrations. This is needed to decrease the potential tritium permeation to the surroundings and large releases from unforeseen accident scenarios. Extraction is complicated due to required low tritium concentration limits and because of the high affinity of tritium formore » the blanket. This work identified, developed and tested the use of ceramic lithium ion conductors capable of recovering hydrogen and deuterium through an electrolysis step at high temperatures.« less

Direct Lit Electrolysis In A Metallic Lithium Fusion Blanket

DOE Office of Scientific and Technical Information (OSTI.GOV)

Colon-Mercado, H.; Babineau, D.; Elvington, M.

2015-10-13

A process that simplifies the extraction of tritium from molten lithium based breeding blankets was developed.  The process is based on the direct electrolysis of lithium tritide using a ceramic Li ion conductor that replaces the molten salt extraction step. Extraction of tritium in the form of lithium tritide in the blankets/targets of fission/fusion reactors is critical in order to maintained low concentrations.  This is needed to decrease the potential tritium permeation to the surroundings and large releases from unforeseen accident scenarios. Because of the high affinity of tritium for the blanket, extraction is complicated at the required low levels. This workmore » identified, developed and tested the use of ceramic lithium ion conductors capable of recovering the hydrogen and deuterium thru an electrolysis step at high temperatures. « less

Molten metal burns: further evidence of industrial foundries' failure to comply with Occupational Safety and Health Administration regulations.

PubMed

Faulkner, B C; Drake, D B; Gear, A J; Watkins, F H; Edlich, R F

1997-01-01

The purpose of this report is to describe another case of a molten metal burn to the foot of a foundry worker. The foundry in which he worked failed to comply with Occupational Safety and Health Administration regulations with regard to protective apparel. This injury could have been prevented with annual, unscheduled inspections by the Occupational Safety and Health Administration and with enforcement of additional regulations regarding protective apparel.

Insulator coating for high temperature alloys method for producing insulator coating for high temperature alloys

DOEpatents

Park, J.H.

1998-06-23

A method for fabricating an electrically insulating coating on a surface is disclosed comprising coating the surface with a metal, and reacting the metal coated surface with a nonmetal so as to create a film on the metal-coated surface. Alternatively, the invention provides for a method for producing a noncorrosive, electrically insulating coating on a surface saturated with a nonmetal comprising supplying a molten fluid, dissolving a metal in the molten fluid to create a mixture, and contacting the mixture with the saturated surface. Lastly, the invention provides an electrically insulative coating comprising an underlying structural substrate coated with an oxide or nitride compound. 2 figs.

Infiltration processing of metal matrix composites using coated ceramic particulates

NASA Astrophysics Data System (ADS)

Leon-Patino, Carlos Alberto

2001-07-01

A new process was developed to fabricate particulate metal matrix composites (MMCs). The process involves three steps: (1) modifying the particulate surface by metal coating, (2) forming a particulate porous compact; and (3) introducing metal into the channel network by vacuum infiltration. MMCs with different reinforcements, volume fractions, and sizes can be produced by this technique. Powders of alumina and silicon carbide were successfully coated with nickel and copper in preparation for infiltration with molten aluminum. Electroless Ni and Cu deposition was used since it enhances the wettability of the reinforcements for composite fabrication. While Cu deposits were polycrystalline, traces of phosphorous co-deposited from the electroless bath gave an amorphous Ni-P coating. The effect of metal coating on wetting behavior was evaluated at 800°C on plain and metal-coated ceramic plates using a sessile drop technique. The metallic films eliminated the non-wetting behavior of the uncoated ceramics, leading to equilibrium contact angles in the order of 12° and below 58° for Ni and Cu coated ceramics, respectively. The spreading data indicated that local diffusion at the triple junction was the governing mechanism of the wetting process. Precipitation of intermetallic phases in the drop/ceramic interface delayed the formation of Al4C3. Infiltration with molten Al showed that the coated-particulates are suitable as reinforcing materials for fabricating MMCs, giving porosity-free components with a homogeneously distributed reinforcing phase. The coating promoted easy metal flow through the preform, compared to the non-infiltration behavior of the uncoated counterparts. Liquid state diffusion kinetics due to temperature dependent viscosity forces controlled the infiltration process. Microstructural analysis indicated the formation of intermetallic phases such as CuAl 2, in the case of Cu coating, and Ni2Al3 and NiAl 3 when Ni-coated powders were infiltrated. The overall Ni and Cu content increased from bottom to top of the samples due to dissolution of the metal film by the stream of liquid Al during infiltration. The strengths of the Al/Ni-SiC composites, measured by four-point bending, were 205 and 225 MPa for samples reinforced with 78 mum and 49 mum Ni-SiC, respectively. The mode of fracture was mainly controlled by SiC particle fracture.

Nickel-plating for active metal dissolution resistance in molten fluoride salts

NASA Astrophysics Data System (ADS)

Olson, Luke; Sridharan, Kumar; Anderson, Mark; Allen, Todd

2011-04-01

Ni electroplating of Incoloy-800H was investigated with the goal of mitigating Cr dissolution from this alloy into molten 46.5%LiF-11.5%NaF-42%KF eutectic salt, commonly referred to as FLiNaK. Tests were conducted in graphite crucibles at a molten salt temperature of 850 °C. The crucible material graphite accelerates the corrosion process due to the large activity difference between the graphite and the alloy. For the purposes of providing a baseline for this study, un-plated Incoloy-800H and a nearly pure Ni-alloy, Ni-201 were also tested. Results indicate that Ni-plating has the potential to significantly improve the corrosion resistance of Incoloy-800H in molten fluoride salts. Diffusion of Cr from the alloy through the Ni-plating does occur and if the Ni-plating is thin enough this Cr eventually dissolves into the molten salt. The post-corrosion test microstructure of the Ni-plating, particularly void formation was also observed to depend on the plating thickness. Diffusion anneals in a helium environment of Ni-plated Incoloy-800H and an Fe-Ni-Cr model alloy were also investigated to understand Cr diffusion through the Ni-plating. Further enhancements in the efficacy of the Ni-plating as a protective barrier against Cr dissolution from the alloy into molten fluoride salts can be achieved by thermally forming a Cr 2O 3 barrier film on the surface of the alloy prior to Ni electroplating.

Method and apparatus for removal of gaseous, liquid and particulate contaminants from molten metals

DOEpatents

Hobson, D.O.; Alexeff, I.; Sikka, V.K.

1987-08-10

Method and apparatus for removal of nonelectrically-conducting gaseous, liquid, and particulate contaminants from molten metal compositions by applying a force thereto. The force (commonly referred to as the Lorentz Force) exerted by simultaneous application of an electric field and a magnetic field on a molten conductor causes an increase, in the same direction as the force, in the apparent specific gravity thereof, but does not affect the nonconducting materials. This difference in apparent densities cause the nonconducting materials to ''float'' in the opposite direction from the Lorentz Force at a rapid rate. Means are further provided for removal of the contaminants and prevention of stirring due to rotational forces generated by the applied fields. 6 figs.

Method and apparatus for removal of gaseous, liquid and particulate contaminants from molten metals

DOEpatents

Hobson, David O.; Alexeff, Igor; Sikka, Vinod K.

1988-01-01

Method and apparatus for removal of nonelectrically-conducting gaseous, liquid, and particulate contaminants from molten metal compositions by applying a force thereto. The force (commonly referred to as the Lorentz Force) exerted by simultaneous application of an electric field and a magnetic field on a molten conductor causes an increase, in the same direction as the force, in the apparent specific gravity thereof, but does not affect the nonconducting materials. This difference in apparent densities cause the nonconducting materials to "float" in the opposite direction from the Lorentz Force at a rapid rate. Means are further provided for removal of the contaminants and prevention of stirring due to rotational forces generated by the applied fields.

Preparation of Ferrotitanium from Ilmenite by Electrolysis-Assisted Calciothermic Reduction in CaCl2-NaCl Molten Salt

NASA Astrophysics Data System (ADS)

Zhou, Zhongren; Hua, Yixin; Xu, Cunying; Li, Jian; Li, Yan; Gong, Kai; Ru, Juanjian; Xiong, Li

2016-02-01

Electrolysis-assisted calciothermic reduction method is proposed and successfully used to prepare ferrotitanium alloy from ilmenite by using equal-molar CaCl2-NaCl molten salt as electrolyte, molybdenum rod as cathode, and graphite as anode at 973 K with cell voltages of 3.2-4.4 V under inert atmosphere. Thermodynamics analysis of the process is presented, and the products obtained are examined with x-ray diffraction, scanning electron microscopy, and energy-dispersive spectroscopy. It is demonstrated that the calciothermic reduction of ilmenite is a stepwise process since intermediate CaTiO3 is observed in the products partially reduced. In the calciothermic reduction process, the reduction of FeTiO3 first gives rise to the formation of Fe and CaTiO3, which as intermediates will further react with calcium metal to form ferrotitanium alloys. This is in good agreement with the prediction of thermodynamics. Experimental results also show that increasing cell voltage can accelerate the formation of calcium metal through electrolysis of CaO and CaCl2 and, hence, promote the calciothermic reduction of ilmenite. As the electrolytic zone and reduction zone are combined in the same bath, the theoretical energy requirement for the production of FeTi in the calciothermic process is lower than that in the aluminothermic process.

Energy and Process Optimization and Benchmarking of Army Industrial Processes

DTIC Science & Technology

2006-09-01

casting is a metal part formed by pouring molten iron, steel, aluminum, zinc , titanium, magnesium, copper, brass, bronze or cobalt, in nearly all...blanketing techniques. The loss of high-priced alloys is also mini- mized, while slag or dross rates are cut in half to help decrease disposal costs...fabricated of iron and steel; hot dip coating such items with aluminum, lead, or zinc ; retin- ning cans and utensils; (3) engraving, chasing and

Thermophysical Property Measurements of Silicon-Transition Metal Alloys

NASA Technical Reports Server (NTRS)

Banish, R. Michael; Erwin, William R.; Sansoucie, Michael P.; Lee, Jonghyun; Gave, Matthew A.

2014-01-01

Metals and metallic alloys often have high melting temperatures and highly reactive liquids. Processing reactive liquids in containers can result in significant contamination and limited undercooling. This is particularly true for molten silicon and it alloys. Silicon is commonly termed "the universal solvent". The viscosity, surface tension, and density of several silicon-transition metal alloys were determined using the Electrostatic Levitator system at the Marshall Space Flight Center. The temperature dependence of the viscosity followed an Arrhenius dependence, and the surface tension followed a linear temperature dependence. The density of the melts, including the undercooled region, showed a linear behavior as well. Viscosity and surface tension values were obtain for several of the alloys in the undercooled region.

Positive electrode current collector for liquid metal cells

DOEpatents

Shimotake, Hiroshi; Bartholme, Louis G.

1984-01-01

A current collector for the positive electrode of an electrochemical cell with a positive electrode including a sulfide. The cell also has a negative electrode and a molten salt electrolyte including halides of a metal selected from the alkali metals and the alkaline earth metals in contact with both the positive and negative electrodes. The current collector has a base metal of copper, silver, gold, aluminum or alloys thereof with a coating thereon of iron, nickel, chromium or alloys thereof. The current collector when subjected to cell voltage forms a sulfur-containing compound on the surface thereby substantially protecting the current collector from further attack by sulfur ions during cell operation. Both electroless and electrolytic processes may be used to deposit coatings.

Formation of metallic and metallic-glass hollow spheres and their solidification characteristics

NASA Technical Reports Server (NTRS)

Lee, M. C.

1985-01-01

Various metals and metallic glass systems have bene processed into hollow spheres with sizes ranging from 3 mm to 440 microns in diameter. The technique for the formation of the large hollow spheres, in general, is based on the fluid-dynamic instability of a hollow annular jet. A refined technique has also been developed for microshell formation, in which discrete bubbles are injected into the stream of the molten material and individually 'flushed' out at a frequency related to the Rayleigh jet instability. The surfaces of those spheres of all sizes exhibit a range of contrasting solidification behaviors and characteristics. Metal shells of varying materials, sizes, aspect ratios, sphericity and concentricity have many useful and novel applications.

Directional Electrostatic Accretion Process Employing Acoustic Droplet Formation

NASA Technical Reports Server (NTRS)

Oeftering, Richard (Inventor)

1998-01-01

The present invention is directed to an apparatus for manufacturing a free standing solid metal part. In the present invention, metal droplets are ejected in a nozzleless fashion from a free surface pool of molten metal by applying focused acoustic radiation pressure. The acoustic radiation pressure is produced by high intensity acoustic tone bursts emitted from an acoustic source positioned at the bottom of the pool which directs the acoustic energy at the pool surface. The metal droplets are electrostatically charged so their trajectory can be controlled by electric fields that guide the droplets to predetermined points on a target. The droplets impinge upon the target and solidify with the target material. The accretion of the electrostatically directed solidified droplets forms the free standing metal part.

40 CFR 471.51 - Effluent limitations representing the degree of effluent reduction attainable by the application...

Code of Federal Regulations, 2014 CFR

2014-07-01

...) Molten salt rinse. Subpart E—BPT Pollutant or pollutant property Maximum for any 1 day Maximum for monthly average mg/off-kg (pounds per million off-pounds) of refractory metals treated with molten salt...

40 CFR 471.51 - Effluent limitations representing the degree of effluent reduction attainable by the application...

Code of Federal Regulations, 2012 CFR

2012-07-01

...) Molten salt rinse. Subpart E—BPT Pollutant or pollutant property Maximum for any 1 day Maximum for monthly average mg/off-kg (pounds per million off-pounds) of refractory metals treated with molten salt...

Calcium-bismuth electrodes for large-scale energy storage (liquid metal batteries)

NASA Astrophysics Data System (ADS)

Kim, Hojong; Boysen, Dane A.; Ouchi, Takanari; Sadoway, Donald R.

2013-11-01

Calcium is an attractive electrode material for use in grid-scale electrochemical energy storage due to its low electronegativity, earth abundance, and low cost. The feasibility of combining a liquid Ca-Bi positive electrode with a molten salt electrolyte for use in liquid metal batteries at 500-700 °C was investigated. Exhibiting excellent reversibility up to current densities of 200 mA cm-2, the calcium-bismuth liquid alloy system is a promising positive electrode candidate for liquid metal batteries. The measurement of low self-discharge current suggests that the solubility of calcium metal in molten salt electrolytes can be sufficiently suppressed to yield high coulombic efficiencies >98%. The mechanisms giving rise to Ca-Bi electrode overpotentials were investigated in terms of associated charge transfer and mass transport resistances. The formation of low density Ca11Bi10 intermetallics at the electrode-electrolyte interface limited the calcium deposition rate capability of the electrodes; however, the co-deposition of barium into bismuth from barium-containing molten salts suppressed Ca-Bi intermetallic formation thereby improving the discharge capacity.

Lithium-coated polymeric matrix as a minimum volume-change and dendrite-free lithium metal anode

PubMed Central

Liu, Yayuan; Lin, Dingchang; Liang, Zheng; Zhao, Jie; Yan, Kai; Cui, Yi

2016-01-01

Lithium metal is the ideal anode for the next generation of high-energy-density batteries. Nevertheless, dendrite growth, side reactions and infinite relative volume change have prevented it from practical applications. Here, we demonstrate a promising metallic lithium anode design by infusing molten lithium into a polymeric matrix. The electrospun polyimide employed is stable against highly reactive molten lithium and, via a conformal layer of zinc oxide coating to render the surface lithiophilic, molten lithium can be drawn into the matrix, affording a nano-porous lithium electrode. Importantly, the polymeric backbone enables uniform lithium stripping/plating, which successfully confines lithium within the matrix, realizing minimum volume change and effective dendrite suppression. The porous electrode reduces the effective current density; thus, flat voltage profiles and stable cycling of more than 100 cycles is achieved even at a high current density of 5 mA cm−2 in both carbonate and ether electrolyte. The advantages of the porous, polymeric matrix provide important insights into the design principles of lithium metal anodes. PMID:26987481

Lithium-coated polymeric matrix as a minimum volume-change and dendrite-free lithium metal anode

DOE PAGES

Liu, Yayuan; Lin, Dingchang; Liang, Zheng; ...

2016-03-18

Lithium metal is the ideal anode for the next generation of high-energy-density batteries. Nevertheless, dendrite growth, side reactions and infinite relative volume change have prevented it from practical applications. Here, we demonstrate a promising metallic lithium anode design by infusing molten lithium into a polymeric matrix. The electrospun polyimide employed is stable against highly reactive molten lithium and, via a conformal layer of zinc oxide coating to render the surface lithiophilic, molten lithium can be drawn into the matrix, affording a nano-porous lithium electrode. Importantly, the polymeric backbone enables uniform lithium stripping/plating, which successfully confines lithium within the matrix, realizingmore » minimum volume change and effective dendrite suppression. The porous electrode reduces the effective current density; thus, flat voltage profiles and stable cycling of more than 100 cycles is achieved even at a high current density of 5 mA cm -2 in both carbonate and ether electrolyte. Furthermore, the advantages of the porous, polymeric matrix provide important insights into the design principles of lithium metal anodes.« less

Lithium-coated polymeric matrix as a minimum volume-change and dendrite-free lithium metal anode

DOE Office of Scientific and Technical Information (OSTI.GOV)

Liu, Yayuan; Lin, Dingchang; Liang, Zheng

Lithium metal is the ideal anode for the next generation of high-energy-density batteries. Nevertheless, dendrite growth, side reactions and infinite relative volume change have prevented it from practical applications. Here, we demonstrate a promising metallic lithium anode design by infusing molten lithium into a polymeric matrix. The electrospun polyimide employed is stable against highly reactive molten lithium and, via a conformal layer of zinc oxide coating to render the surface lithiophilic, molten lithium can be drawn into the matrix, affording a nano-porous lithium electrode. Importantly, the polymeric backbone enables uniform lithium stripping/plating, which successfully confines lithium within the matrix, realizingmore » minimum volume change and effective dendrite suppression. The porous electrode reduces the effective current density; thus, flat voltage profiles and stable cycling of more than 100 cycles is achieved even at a high current density of 5 mA cm -2 in both carbonate and ether electrolyte. Furthermore, the advantages of the porous, polymeric matrix provide important insights into the design principles of lithium metal anodes.« less

Apparatus and method for reprocessing and separating spent nuclear fuels. [Patent application

DOEpatents

Krikorian, O.H.; Grens, J.Z.; Parrish, W.H. Sr.; Coops, M.S.

1982-01-19

A method and apparatus for separating and reprocessing spent nuclear fuels includes a separation vessel housing a molten metal solvent in a reaction region, a reflux region positioned above and adjacent to the reaction region, and a porous filter member defining the bottom of the separation vessel in a supporting relationship with the metal solvent. Spent fuels are added to the metal solvent. A nonoxidizing nitrogen-containing gas is introduced into the separation vessel, forming solid actinide nitrides in the metal solvent from actinide fuels, while leaving other fission products in solution. A pressure of about 1.1 to 1.2 atm is applied in the reflux region, forcing the molten metal solvent and soluble fission products out of the vessel, while leaving the solid actinide nitrides in the separation vessel.

Electrochemical Impedance Spectroscopic Study on Eu 2+ and Sr 2+ Using Liquid Metal Cathodes in Molten Chlorides

NASA Astrophysics Data System (ADS)

Matsumiya, Masahiko; Takagi, Ryuzo

2000-08-01

For the pyrochemical reprocessing of spent metallic nuclear fuels in molten salt baths it is important to investigate the behavior of the electrochemically negative elements Eu and Sr, which are significant fission products. Voltammetric and chronopotentiometric studies have shown that the reduction of Eu 2+ and Sr 2+ on liquid Pb cathodes in molten chloride baths at 1073 K follows the alloy formation reaction: Eu 2+ + 2e- + 3Pb → EuPb 3 and Sr 2+ + 2e- + 3Pb → SrPb 3 . In the present work these alloy formation reactions were studiedby electrochemical impedance spectroscopy. Analysis of the spectra showed that the electronic exchange of Eu 2+ /Eu and Sr 2+ /Sr is quasi-re-versible. Moreover, the experimental results allowed the determination of the kinetic parameters of EU 2+ /EU and Sr 2+ /Sr, the diffusion coefficients of these species in molten chloride baths, and also the diffusion layer thickness.

THERMAL DECOMPOSITION OF URANIUM COMPOUNDS

DOEpatents

Magel, T.T.; Brewer, L.

1959-02-10

A method is presented of preparing uranium metal of high purity consisting contacting impure U metal with halogen vapor at between 450 and 550 C to form uranium halide vapor, contacting the uranium halide vapor in the presence of H/sub 2/ with a refractory surface at about 1400 C to thermally decompose the uranium halides and deposit molten U on the refractory surface and collecting the molten U dripping from the surface. The entire operation is carried on at a sub-atmospheric pressure of below 1 mm mercury.

Molten carbonate fuel cell reduction of nickel deposits

DOEpatents

Smith, James L.; Zwick, Stanley A.

1987-01-01

A molten carbonate fuel cell with anode and cathode electrodes and an eleolyte formed with two tile sections, one of the tile sections being adjacent the anode and limiting leakage of fuel gas into the electrolyte with the second tile section being adjacent the cathode and having pores sized to permit the presence of oxygen gas in the electrolyte thereby limiting the formation of metal deposits caused by the reduction of metal compositions migrating into the electrolyte from the cathode.

Study of aluminum particle combustion in solid propellant plumes using digital in-line holography and imaging pyrometry

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen, Yi; Guildenbecher, Daniel R.; Hoffmeister, Kathryn N. G.

The combustion of molten metals is an important area of study with applications ranging from solid aluminized rocket propellants to fireworks displays. Our work uses digital in-line holography (DIH) to experimentally quantify the three-dimensional position, size, and velocity of aluminum particles during combustion of ammonium perchlorate (AP) based solid-rocket propellants. Additionally, spatially resolved particle temperatures are simultaneously measured using two-color imaging pyrometry. To allow for fast characterization of the properties of tens of thousands of particles, automated data processing routines are proposed. In using these methods, statistics from aluminum particles with diameters ranging from 15 to 900 µm are collectedmore » at an ambient pressure of 83 kPa. In the first set of DIH experiments, increasing initial propellant temperature is shown to enhance the agglomeration of nascent aluminum at the burning surface, resulting in ejection of large molten aluminum particles into the exhaust plume. The resulting particle number and volume distributions are quantified. In the second set of simultaneous DIH and pyrometry experiments, particle size and velocity relationships as well as temperature statistics are explored. The average measured temperatures are found to be 2640 ± 282 K, which compares well with previous estimates of the range of particle and gas-phase temperatures. The novel methods proposed here represent new capabilities for simultaneous quantification of the joint size, velocity, and temperature statistics during the combustion of molten metal particles. The proposed techniques are expected to be useful for detailed performance assessment of metalized solid-rocket propellants.« less

Study of aluminum particle combustion in solid propellant plumes using digital in-line holography and imaging pyrometry

DOE PAGES

Chen, Yi; Guildenbecher, Daniel R.; Hoffmeister, Kathryn N. G.; ...

2017-05-05

The combustion of molten metals is an important area of study with applications ranging from solid aluminized rocket propellants to fireworks displays. Our work uses digital in-line holography (DIH) to experimentally quantify the three-dimensional position, size, and velocity of aluminum particles during combustion of ammonium perchlorate (AP) based solid-rocket propellants. Additionally, spatially resolved particle temperatures are simultaneously measured using two-color imaging pyrometry. To allow for fast characterization of the properties of tens of thousands of particles, automated data processing routines are proposed. In using these methods, statistics from aluminum particles with diameters ranging from 15 to 900 µm are collectedmore » at an ambient pressure of 83 kPa. In the first set of DIH experiments, increasing initial propellant temperature is shown to enhance the agglomeration of nascent aluminum at the burning surface, resulting in ejection of large molten aluminum particles into the exhaust plume. The resulting particle number and volume distributions are quantified. In the second set of simultaneous DIH and pyrometry experiments, particle size and velocity relationships as well as temperature statistics are explored. The average measured temperatures are found to be 2640 ± 282 K, which compares well with previous estimates of the range of particle and gas-phase temperatures. The novel methods proposed here represent new capabilities for simultaneous quantification of the joint size, velocity, and temperature statistics during the combustion of molten metal particles. The proposed techniques are expected to be useful for detailed performance assessment of metalized solid-rocket propellants.« less

Application of Ionic Liquids in Hydrometallurgy

PubMed Central

Park, Jesik; Jung, Yeojin; Kusumah, Priyandi; Lee, Jinyoung; Kwon, Kyungjung; Lee, Churl Kyoung

2014-01-01

Ionic liquids, low temperature molten salts, have various advantages manifesting themselves as durable and environmentally friendly solvents. Their application is expanding into various fields including hydrometallurgy due to their unique properties such as non-volatility, inflammability, low toxicity, good ionic conductivity, and wide electrochemical potential window. This paper reviews previous literatures and our recent results adopting ionic liquids in extraction, synthesis and processing of metals with an emphasis on the electrolysis of active/light, rare earth, and platinum group metals. Because the research and development of ionic liquids in this area are still emerging, various, more fundamental approaches are expected to popularize ionic liquids in the metal manufacturing industry. PMID:25177864

ELECTRODEPOSITION OF NICKEL ON URANIUM

DOEpatents

Gray, A.G.

1958-08-26

A method is described for preparing uranium objects prior to nickel electroplating. The process consiats in treating the surface of the uranium with molten ferric chloride hexahydrate, at a slightiy elevated temperature. This treatment etches the metal surface providing a structure suitable for the application of adherent electrodeposits and at the same time plates the surface with a thin protective film of iron.

Fluid Bed Dehydration of Magnesium Chloride

NASA Astrophysics Data System (ADS)

Adham, K.; Lee, C.; O'Keefe, K.

Molten salt electrolysis of MgCl2 is commonly used for the production of magnesium metal. However, the electrolysis feed must be completely dry with minimum oxygen content. Therefore, complete dehydration of the MgCl2 brine or the hydrated prill is a required process, which is very challenging because of the ease of thermal degradation due to hydrolysis of magnesium chloride.

A Reaction Between High Mn-High Al Steel and CaO-SiO2-Type Molten Mold Flux: Part II. Reaction Mechanism, Interface Morphology, and Al2O3 Accumulation in Molten Mold Flux

NASA Astrophysics Data System (ADS)

Kang, Youn-Bae; Kim, Min-Su; Lee, Su-Wan; Cho, Jung-Wook; Park, Min-Seok; Lee, Hae-Geon

2013-04-01

Following a series of laboratory-scale experiments, the mechanism of a chemical reaction 4[{Al}] + 3({SiO}_2) = 3[{Si}] + 2({Al}_2{O}_3) between high-alloyed TWIP (TWin-Induced Plasticity) steel containing Mn and Al and molten mold flux composed mainly of CaO-SiO2 during the continuous casting process is discussed in the present article in the context of kinetic analysis, morphological evolution at the reaction interface. By the kinetic analysis using a two-film theory, a rate-controlling step of the chemical reaction at the interface between the molten steel and the molten flux is found to be mass transport of Al in a boundary layer of the molten steel, as long as the molten steel and the molten flux phases are concerned. Mass transfer coefficient of the Al in the boundary layer (k_{{Al}}) is estimated to be 0.9 to 1.2 × 10-4 m/s at 1773 K (1500 ^{circ}C). By utilizing experimental data at various temperatures, the following equation is obtained for the k_{{Al}}; ln k_{{Al}} = -14,290/T - 1.1107. Activation energy for the mass transfer of Al in the boundary layer is 119 kJ/mol, which is close to a value of activation energy for mass transfer in metal phase. The composition evolution of Al in the molten steel was well explained by the mechanism of Al mass transfer. On the other hand, when the concentration of Al in the steel was high, a significant deviation of the composition evolution of Al in the molten steel was observed. By observing reaction interface between the molten steel and the molten flux, it is thought that the chemical reaction controlled by the mass transfer of Al seemed to be disturbed by formation of a solid product layer of MgAl2O4. A model based on a dynamic mass balance and the reaction mechanism of mass transfer of Al in the boundary layer for the low Al steel was developed to predict (pct Al2O3) accumulation rate in the molten mold flux.

Rapid solidification processing system for producing molds, dies and related tooling

DOEpatents

McHugh, Kevin M.

2004-06-08

A system for the spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the in-flight atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as powders, whiskers or fibers.

Wetting of a Charged Surface of Glassy Carbon by Molten Alkali-Metal Chlorides

NASA Astrophysics Data System (ADS)

Stepanov, V. P.

2018-03-01

Values of the contact angle of wetting of a surface of glassy carbon by molten chlorides of lithium, sodium, potassium, and cesium are measured by the meniscus weight method to determine the common factors of wettability of solid surfaces by ionic melts upon a change in the salt phase composition and a jump in electric potential. It is found that with a potential shift in the positive direction the shape of the curve of the contact angle's dependence on the potential varies upon substitution of one salt by another: the angle of wetting shrinks monotonously in lithium chloride but remains constant in molten cesium chloride. This phenomenon is explained by the hypothesis that the nature of the halide anion adsorption on the positively charged surface of an electrode is chemical and not electrostatic. It is shown that the adsorption process is accompanied by charge transfer through the interface, with covalent bonding between the adsorbent and adsorbate.

Plasma Sprayed Hydroxyapatite Coatings: Influence of Spraying Power on Microstructure

NASA Astrophysics Data System (ADS)

Mohd, S. M.; Abd, M. Z.; Abd, A. N.

2010-03-01

The plasma sprayed hydroxyapatite (HA) coatings are used on metallic implants to enhance the bonding between the implant and bone in human body. The coating process was implemented at different spraying power for each spraying condition. The coatings formed from a rapid solidification of molten and partly molten particles that impact on the surface of substrate at high velocity and high temperature. The study was concentrated on different spraying power that is between 23 to 31 kW. The effect of different power on the coatings microstructure was investigated using scanning electron microscope (SEM) and phase composition was evaluated using X-ray diffraction (XRD) analysis. The coatings surface morphology showed distribution of molten, partially melted particles and some micro-cracks. The produced coatings were found to be porous as observed from the cross-sectional morphology. The coatings XRD results indicated the presence of crystalline phase of HA and each of the patterns was similar to the initial powder. Regardless of different spraying power, all the coatings were having similar XRD patterns.

Study of the Effect of Molten Copper Chloride Immersion Test on Alloys with High Nickel Content with and without Surface Coatings

NASA Astrophysics Data System (ADS)

Siantar, Edwin

The demand for hydrogen as a clean energy carrier has increased greatly. The Cu-Cl cycle is a promising thermochemical cycle that is currently being developed to be the large-scale method of hydrogen production. The lifetime of materials for the pipes transporting molten CuCl is an important parameter for an economic design of a commercial thermochemical Cu-Cl hydrogen plant. This research is an examination of candidate materials following an immersion test in molten CuCl at 500 °C for 100 h. Two alloys, Ni based super-alloy (Inconel 625) and super austenitic stainless steel (AL6XN) were selected as the base metal. There were two types of coating applied to improve the corrosion resistance of the base metals during molten CuCl exposure. A metallic of Diamalloy 4006 and two ceramic of yttria stabilized zirconia and alumina coatings were applied to the base metal using thermal spray methods. An immersion apparatus was designed and constructed to perform an immersion test that has a condition similar to those in a hydrogen plant. After the immersion test, the materials were evaluated using an electrochemical method in combination with ex-situ surface analysis. The surface condition including elemental composition, film structure and resistivity of the materials were examined and compared. The majority of the coatings were damaged and fell off. Cracks were found in the original coated specimens indicating the sample geometry may have affected the integrity of the sprayed coating. When the coating cracked, it provided a pathway for the molten CuCl to go under the coating and react with the surface underneath the coating. Copper deposits and iron chloride that were found on the sample surfaces suggest that there were corrosion reactions that involved the metal dissolution and reduction of copper during immersion test. The results also suggest that Inconel 625 performed better than stainless steel AL6XN. Both Diamalloy 4006 and YSZ (ZrO2 18TiO2 10Y2O3) coatings seemed to provide better protection to the underlying base metal than alumina (Al2O3 3TiO2) coating.

Direct printing of miniscule aluminum alloy droplets and 3D structures by StarJet technology

NASA Astrophysics Data System (ADS)

Gerdes, B.; Zengerle, R.; Koltay, P.; Riegger, L.

2018-07-01

Drop-on demand printing of molten metal droplets could be used for prototyping 3D objects as a promising alternative to laser melting technologies. However, to date, only few printheads have been investigated for this purpose, and they used only a limited range of materials. The pneumatically actuated StarJet technology enables the direct and non-contact printing of molten metal microdroplets from metal melts at high temperatures. StarJet printheads utilize nozzle chips featuring a star-shaped orifice geometry that leads to formation of droplets inside the nozzle with high precision. In this paper, we present a novel StarJet printhead for printing aluminum (Al) alloys featuring a hybrid design with a ceramic reservoir for the molten metal and an outer shell fabricated from stainless steel. The micro machined nozzle chip is made from silicon carbide (SiC). This printhead can be operated at up to 950 °C, and is capable of printing high melting point metals like Al alloys in standard laboratory conditions. In this work, an aluminum–silicon alloy that features 12% silicon (AlSi12) is printed. The printhead, nozzle, and peripheral actuation system are optimized for stable generation of AlSi12 droplets with high monodispersity, low angular deviation, and miniaturized droplet diameters. As a result, a stable drop-on-demand printing of droplets exhibiting diameters of d droplet  =  702 µm  ±  1% is demonstrated at 5 Hz with a low angular deviation of 0.3°, when a nozzle chip with 500 µm orifice diameter is used. Furthermore, AlSi12 droplets featuring d droplet  =  176 µm  ±  7% are printed when using a nozzle chip with an orifice diameter of 130 µm. Moreover, we present directly printed objects from molten Al alloy droplets, such as high aspect ratio, free-standing walls (aspect ratio 12:1), and directly printed, flexible springs, to demonstrate the principle of 3D printing with molten metal droplets.

Molten salt electrodeposition of high temperature superconductors. Final report, 7 September 1990-30 November 1992

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tench, D.M.; Kendig, M.W.; Jeanjaquet, S.

1993-06-01

The overall objective of this project was to develop a process for direct electrodeposition of Y-Ba-Cu superconducting oxides from a molten salt at relatively low temperatures (300-550 deg C). An important finding was that cathodic deposition of metallic oxides, rather than free metals, generally occurs from nitrate melts, apparently via reduction of metal nitrato complexes. Oxide deposition was confirmed for Cu as CuO, Y as Y2O3, and Co as Co3O4, and apparently also occurs for Ba. Deposition of mixed Ba-Y-Cu oxides was demonstrated on both Cu and Pt substrates. Data were compiled that provide a good basis for designing schemesmore » for deposition of various mixed oxides from nitrate melts. A sequential anodic injection method was conceived for depositing ultrathin mixed oxide layers, which can be viewed as an analog of molecular beam epitaxy. Results obtained with this approach were encouraging but were inconclusive because of contamination with Gd from the Y injection anode. Based on the results of this program and literature studies, cathodic metal oxide deposition from nitrate melts is a general phenomenon that could ultimately prove to be a practical means of preparing a variety of single and mixed anhydrous metal oxide films. It is recommended that future work focus initially on deposition of perovskite materials, which are of considerable practical interest and involve only two metallic components so that the required deposition schemes are inherently simpler.« less

Near-Net-Shape Production of Hollow Titanium Alloy Components via Electrochemical Reduction of Metal Oxide Precursors in Molten Salts

NASA Astrophysics Data System (ADS)

Hu, Di; Xiao, Wei; Chen, George Z.

2013-04-01

Metal oxide precursors (ca. 90 wt pct Ti, 6 wt pct Al, and 4 wt pct V) were prepared with a hollow structure in various shapes such as a sphere, miniature golf club head, and cup using a one-step solid slip-casting process. The precursors were then electro-deoxidized in molten calcium chloride [3.2 V, 1173 K (900 °C)] against a graphite anode. After 24 hours of electrolysis, the near-net-shape Ti-6Al-4V product maintained its original shape with controlled shrinkage. Oxygen contents in the Ti-6Al-4V components were typically below 2000 ppm. The maximum compressive stress and modulus of electrolytic products obtained in this work were approximately 243 MPa and 14 GPa, respectively, matching with the requirement for medical implants. Further research directions are discussed for mechanical improvement of the products via densification during or after electrolysis. This simple, fast, and energy-efficient near-net-shape manufacturing method could allow titanium alloy components with desired geometries to be prepared directly from a mixture of metal oxides, promising an innovative technology for the low-cost production of titanium alloy components.

Examination of nanosecond laser melting thresholds in refractory metals by shear wave acoustics

NASA Astrophysics Data System (ADS)

Abdullaev, A.; Muminov, B.; Rakhymzhanov, A.; Mynbayev, N.; Utegulov, Z. N.

2017-07-01

Nanosecond laser pulse-induced melting thresholds in refractory (Nb, Mo, Ta and W) metals are measured using detected laser-generated acoustic shear waves. Obtained melting threshold values were found to be scaled with corresponding melting point temperatures of investigated materials displaying dissimilar shearing behavior. The experiments were conducted with motorized control of the incident laser pulse energies with small and uniform energy increments to reach high measurement accuracy and real-time monitoring of the epicentral acoustic waveforms from the opposite side of irradiated sample plates. Measured results were found to be in good agreement with numerical finite element model solving coupled elastodynamic and thermal conduction governing equations on structured quadrilateral mesh. Solid-melt phase transition was handled by means of apparent heat capacity method. The onset of melting was attributed to vanished shear modulus and rapid radial molten pool propagation within laser-heated metal leading to preferential generation of transverse acoustic waves from sources surrounding the molten mass resulting in the delay of shear wave transit times. Developed laser-based technique aims for applications involving remote examination of rapid melting processes of materials present in harsh environment (e.g. spent nuclear fuels) with high spatio-temporal resolution.

Concept Feasibility Report for Electroplating Zirconium onto Uranium Foil - Year 2

DOE Office of Scientific and Technical Information (OSTI.GOV)

Coffey, Greg W.; Meinhardt, Kerry D.; Joshi, Vineet V.

2015-03-01

The Fuel Fabrication Capability within the U.S. High Performance Research Reactor Conversion Program is funded through the National Nuclear Security Administration (NNSA) NA-26 (Office of Material Management and Minimization). An investigation was commissioned to determine the feasibility of using electroplating techniques to apply a coating of zirconium onto depleted uranium/molybdenum alloy (U-10Mo). Electroplating would provide an alternative method to the existing process of hot roll-bonding zirconium foil onto the U-10Mo fuel foil during the fabrication of fuel elements for high-performance research reactors. The objective of this research was to develop a reproducible and scalable plating process that will produce amore » uniform, 25 μm thick zirconium metal coating on U-10Mo foil. In previous work, Pacific Northwest National Laboratory (PNNL) established a molten salt electroplating apparatus and protocol to plate zirconium metal onto molybdenum foil (Coffey 2015). During this second year of the research, PNNL furthered this work by moving to the U-10Mo alloy system (90 percent uranium:10 percent molybdenum). The original plating apparatus was disassembled and re-assembled in a laboratory capable of handling low-level radioactive materials. Initially, the work followed the previous year’s approach, and the salt bath composition was targeted at the eutectic composition (LiF:NaF:ZrF4 = 26:37:37 mol%). Early results indicated that the formation of uranium fluoride compounds would be problematic. Other salt bath compositions were investigated in order to eliminate the uranium fluoride production (LiF:NaF = 61:39 mol% and LiF:NaF:KF = 46.5:11.5:42 mol% ). Zirconium metal was used as the crucible for the molten salt. Three plating methods were used—isopotential, galvano static, and pulsed plating. The molten salt method for zirconium metal application provided high-quality plating on molybdenum in PNNL’s previous work. A key advantage of this approach is that plating can be performed under conditions that would greatly reduce the quantity of intermetallics that form at the interface between the zirconium and U-10Mo; unlike roll bonding, the molten salt plating approach would allow for complete coverage of the U-10Mo foil with zirconium. When utilizing the experimental parameters developed for zirconium plating onto molybdenum, a uranium fluoride reaction product was formed at the Zr/U-10Mo interface. By controlling the initial plating potential, the uranium fluoride could be prevented; however, the targeted zirconium thickness (25 ±12.5 μm) could not be achieved while maintaining 100% coverage.« less

Reoxidation of uranium metal immersed in a Li2O-LiCl molten salt after electrolytic reduction of uranium oxide

NASA Astrophysics Data System (ADS)

Choi, Eun-Young; Jeon, Min Ku; Lee, Jeong; Kim, Sung-Wook; Lee, Sang Kwon; Lee, Sung-Jai; Heo, Dong Hyun; Kang, Hyun Woo; Jeon, Sang-Chae; Hur, Jin-Mok

2017-03-01

We present our findings that uranium (U) metal prepared by using the electrolytic reduction process for U oxide (UO2) in a Li2O-LiCl salt can be reoxidized into UO2 through the reaction between the U metal and Li2O in LiCl. Two salt types were used for immersion of the U metal: one was the salt used for electrolytic reduction, and the other was applied to the unused LiCl salts with various concentrations of Li2O and Li metal. Our results revealed that the degree of reoxidation increases with the increasing Li2O concentration in LiCl and that the presence of the Li metal in LiCl suppresses the reoxidation of the U metal.

Morphology and Orientation Selection of Non-metallic Inclusions in Electrified Molten Metal

NASA Astrophysics Data System (ADS)

Zhao, Z. C.; Qin, R. S.

2017-10-01

The effect of electric current on morphology and orientation selection of non-metallic inclusions in molten metal has been investigated using theoretical modeling and numerical calculation. Two geometric factors, namely the circularity ( fc ) and alignment ratio ( fe ) were introduced to describe the inclusions shape and configuration. Electric current free energy was calculated and the values were used to determine the thermodynamic preference between different microstructures. Electric current promotes the development of inclusion along the current direction by either expatiating directional growth or enhancing directional agglomeration. Reconfiguration of the inclusions to reduce the system electric resistance drives the phenomena. The morphology and orientation selection follow the routine to reduce electric free energy. The numerical results are in agreement with our experimental observations.

40 CFR 471.53 - New source performance standards (NSPS).

Code of Federal Regulations, 2014 CFR

2014-07-01

... TSS 123 97.9 pH (1) (1) 1 Within the range of 7.5 to 10.0 at all times. (p) Molten salt rinse. Subpart... (pounds per million off-pounds) of refractory metals treated with molten salt Copper 0.810 0.386 Nickel 0...

13. VIEW OF THE MOLTEN SALT BATHS USED TO UNIFORMLY ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

13. VIEW OF THE MOLTEN SALT BATHS USED TO UNIFORMLY AND QUICKLY HEAT METALS PRIOR TO WORKING (ROLLING). (9/16/85) - Rocky Flats Plant, Uranium Rolling & Forming Operations, Southeast section of plant, southeast quadrant of intersection of Central Avenue & Eighth Street, Golden, Jefferson County, CO

40 CFR 471.53 - New source performance standards (NSPS).

Code of Federal Regulations, 2012 CFR

2012-07-01

... TSS 123 97.9 pH (1) (1) 1 Within the range of 7.5 to 10.0 at all times. (p) Molten salt rinse. Subpart... (pounds per million off-pounds) of refractory metals treated with molten salt Copper 0.810 0.386 Nickel 0...

Electrolytic method for the production of lithium using a lithium-amalgam electrode

DOEpatents

Cooper, John F.; Krikorian, Oscar H.; Homsy, Robert V.

1979-01-01

A method for recovering lithium from its molten amalgam by electrolysis of the amalgam in an electrolytic cell containing as a molten electrolyte a fused-salt consisting essentially of a mixture of two or more alkali metal halides, preferably alkali metal halides selected from lithium iodide, lithium chloride, potassium iodide and potassium chloride. A particularly suitable molten electrolyte is a fused-salt consisting essentially of a mixture of at least three components obtained by modifying an eutectic mixture of LiI-KI by the addition of a minor amount of one or more alkali metal halides. The lithium-amalgam fused-salt cell may be used in an electrolytic system for recovering lithium from an aqueous solution of a lithium compound, wherein electrolysis of the aqueous solution in an aqueous cell in the presence of a mercury cathode produces a lithium amalgam. The present method is particularly useful for the regeneration of lithium from the aqueous reaction products of a lithium-water-air battery.

Numerical simulation of spatter formation during fiber laser welding of 5083 aluminum alloy at full penetration condition

NASA Astrophysics Data System (ADS)

Wu, Dongsheng; Hua, Xueming; Huang, Lijin; Zhao, Jiang

2018-03-01

The droplet escape condition in laser welding is established in this paper. A three-dimensional numerical model is developed to study the weld pool convection and spatter formation at full penetration during the fiber laser welding of 5083 aluminum alloy. It is found that when laser power is 9 kW, the bottom of the keyhole is dynamically opened and closed. When the bottom of the keyhole is closed, the molten metal at the bottom of the back keyhole wall flows upwards along the fusion line. When the bottom of the keyhole is opened, few spatters can be seen around the keyhole at the top surface, two flow patterns exists in the rear part of the keyhole: a portion of molten metal flows upwards along the fusion line, other portion of molten metal flows to the bottom of the keyhole, which promote the spatter formation at the bottom of the keyhole rear wall.

Pyrite cathode material for a thermal battery

NASA Astrophysics Data System (ADS)

Pemsler, J. P.; Litchfield, J. K.

1991-02-01

The present invention relates in general to a synthetic cathode material for a molten salt battery and, more particularly, to a process of providing and using synthetic pyrite for use as a cathode in a thermal battery. These batteries, which have been successfully used in a number of military applications, include iron disulfide cathode material obtained as benefacted or from natural occurring pyrite deposits, or as a byproduct of flotation concentrate from the processing of base or noble metal ores.

Study of iron structure stability in high temperature molten lead-bismuth eutectic with oxygen injection using molecular dynamics simulation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Arkundato, Artoto; Su'ud, Zaki; Sudarko

2014-09-30

Corrosion of structural materials in high temperature molten lead-bismuth eutectic is a major problem for design of PbBi cooled reactor. One technique to inhibit corrosion process is to inject oxygen into coolant. In this paper we study and focus on a way of inhibiting the corrosion of iron using molecular dynamics method. For the simulation results we concluded that effective corrosion inhibition of iron may be achieved by injection 0.0532 wt% to 0.1156 wt% oxygen into liquid lead-bismuth. At this oxygen concentration the structure of iron material will be maintained at about 70% in bcc crystal structure during interaction withmore » liquid metal.« less

Treatment of organic waste

DOEpatents

Grantham, LeRoy F.

1979-01-01

An organic waste containing at least one element selected from the group consisting of strontium, cesium, iodine and ruthenium is treated to achieve a substantial reduction in the volume of the waste and provide for fixation of the selected element in an inert salt. The method of treatment comprises introducing the organic waste and a source of oxygen into a molten salt bath maintained at an elevated temperature to produce solid and gaseous reaction products. The gaseous reaction products comprise carbon dioxide and water vapor, and the solid reaction products comprise the inorganic ash constituents of the organic waste and the selected element which is retained in the molten salt. The molten salt bath comprises one or more alkali metal carbonates, and may optionally include from 1 to about 25 wt.% of an alkali metal sulfate.

Sn/MWCNT Nanocomposites Fabricated by Ultrasonic Dispersion of Ni-Coated MWCNTs in Molten Tin

NASA Astrophysics Data System (ADS)

Billah, Md Muktadir; Chen, Quanfang

2018-04-01

Carbon nanotubes (CNTs) are regarded as a desirable filler to develop advanced composites including advanced solders due to their exceptional mechanical properties. However, some issues remain unsolved for metallic composites owing to "wetting" and nonuniform dispersion of CNTs. In this study, electroless nickel coating onto CNTs was used to overcome these issues. Multiwalled carbon nanotubes (MWCNTs) were used for this study, and Ni-coated MWCNTs were dispersed in molten Sn assisted by sonication and compared with MWCNTs without Ni coating. Adding 3 wt.% Ni-coated MWCNTs, which corresponds to 0.6 wt.% pure CNTs, resulted in an increase in tensile strength by 95% and hardness by 123%. Nickel coating also prevented separation of the CNTs from the molten metal due to buoyancy effects, leading to more uniform dispersion.

Computational Modeling of Arc-Slag Interaction in DC Furnaces

NASA Astrophysics Data System (ADS)

Reynolds, Quinn G.

2017-02-01

The plasma arc is central to the operation of the direct-current arc furnace, a unit operation commonly used in high-temperature processing of both primary ores and recycled metals. The arc is a high-velocity, high-temperature jet of ionized gas created and sustained by interactions among the thermal, momentum, and electromagnetic fields resulting from the passage of electric current. In addition to being the primary source of thermal energy, the arc jet also couples mechanically with the bath of molten process material within the furnace, causing substantial splashing and stirring in the region in which it impinges. The arc's interaction with the molten bath inside the furnace is studied through use of a multiphase, multiphysics computational magnetohydrodynamic model developed in the OpenFOAM® framework. Results from the computational solver are compared with empirical correlations that account for arc-slag interaction effects.

Discussion of Carbon Emissions for Charging Hot Metal in EAF Steelmaking Process

NASA Astrophysics Data System (ADS)

Yang, Ling-zhi; Jiang, Tao; Li, Guang-hui; Guo, Yu-feng

2017-07-01

As the cost of hot metal is reduced for iron ore prices are falling in the international market, more and more electric arc furnace (EAF) steelmaking enterprises use partial hot metal instead of scrap as raw materials to reduce costs and the power consumption. In this paper, carbon emissions based on 1,000 kg molten steel by charging hot metal in EAF steelmaking is studied. Based on the analysis of material and energy balance calculation in EAF, the results show that 146.9, 142.2, 137.0, and 130.8 kg/t of carbon emissions are produced at a hot metal ratio of 0 %, 30 %, 50 %, and 70 %, while 143.4, 98.5, 65.81, and 31.5 kg/t of carbon emissions are produced at a hot metal ratio of 0 %, 30 %, 50 %, and 70 % by using gas waste heat utilization (coal gas production) for EAF steelmaking unit process. However, carbon emissions are increased by charging hot metal for the whole blast furnace-electric arc furnace (BF-EAF) steelmaking process. In the condition that the hot metal produced by BF is surplus, as carbon monoxide in gas increased by charging hot metal, the way of coal gas production can be used for waste heat utilization, which reduces carbon emissions in EAF steelmaking unit process.

Recycling of mixed wastes using Quantum-CEP{trademark}

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sameski, B.

1997-02-01

The author describes the process that M4 Environmental Management, Inc., is commercializing for the treatment of mixed wastes. He summarizes the types of wastes which the process can be applied to, the products which come out of the process, and examples of various waste streams which have been processed. The process is presently licensed to treat mixed wastes and the company has in place contracts for such services. The process uses a molten metal bath to catalyze reactions which break the incoming products down to an atomic level, and allow different process steams to be tapped at the output end.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anameric, B.; Kawatra, S.K.

Pig iron nuggets were produced in a laboratory-scale furnace at Michigan Technological University. The process was intended to replicate Kobe Steel's ITmk3 direct ironmaking process. These nuggets were produced from pellets that were made from a mixture of iron oxide, coal, flux and a binder and heated in a furnace with a chamber temperature of 1450{sup o}C. The pellets then self-reduced to produce a solid, high-density, highly metallized (96.5% Fe) pig iron. During the nugget production process, a separate liquid slag phase formed that cleanly separated from the molten metal. The physical and chemical properties of the pig iron nuggetsmore » were similar to pig iron produced by blast furnaces, which is distinct from direct reduced iron (DRI).« less

Metal-filled carbon nanotube based optical nanoantennas: bubbling, reshaping, and in situ characterization.

PubMed

Fan, Zheng; Tao, Xinyong; Cui, Xudong; Fan, Xudong; Zhang, Xiaobin; Dong, Lixin

2012-09-21

Controlled fabrication of metal nanospheres on nanotube tips for optical antennas is investigated experimentally. Resembling soap bubble blowing using a straw, the fabrication process is based on nanofluidic mass delivery at the attogram scale using metal-filled carbon nanotubes (m@CNTs). Two methods have been investigated including electron-beam-induced bubbling (EBIB) and electromigration-based bubbling (EMBB). EBIB involves the bombardment of an m@CNT with a high energy electron beam of a transmission electron microscope (TEM), with which the encapsulated metal is melted and flowed out from the nanotube, generating a metallic particle on a nanotube tip. In the case where the encapsulated materials inside the CNT have a higher melting point than what the beam energy can reach, EMBB is an optional process to apply. Experiments show that, under a low bias (2.0-2.5 V), nanoparticles can be formed on the nanotube tips. The final shape and crystallinity of the nanoparticles are determined by the cooling rate. Instant cooling occurs with a relatively large heat sink and causes the instant shaping of the solid deposit, which is typically similar to the shape of the molten state. With a smaller heat sink as a probe, it is possible to keep the deposit in a molten state. Instant cooling by separating the deposit from the probe can result in a perfect sphere. Surface and volume plasmons characterized with electron energy loss spectroscopy (EELS) prove that resonance occurs between a pair of as-fabricated spheres on the tip structures. Such spheres on pillars can serve as nano-optical antennas and will enable devices such as scanning near-field optical microscope (SNOM) probes, scanning anodes for field emitters, and single molecule detectors, which can find applications in bio-sensing, molecular detection, and high-resolution optical microscopy.

Laboratory simulation of heat exchange for liquids with Pr > 1: Heat transfer

NASA Astrophysics Data System (ADS)

Belyaev, I. A.; Zakharova, O. D.; Krasnoshchekova, T. E.; Sviridov, V. G.; Sukomel, L. A.

2016-02-01

Liquid metals are promising heat transfer agents in new-generation nuclear power plants, such as fast-neutron reactors and hybrid tokamaks—fusion neutron sources (FNSs). We have been investigating hydrodynamics and heat exchange of liquid metals for many years, trying to reproduce the conditions close to those in fast reactors and fusion neutron sources. In the latter case, the liquid metal flow takes place in a strong magnetic field and strong thermal loads resulting in development of thermogravitational convection in the flow. In this case, quite dangerous regimes of magnetohydrodynamic (MHD) heat exchange not known earlier may occur that, in combination with other long-known regimes, for example, the growth of hydraulic drag in a strong magnetic field, make the possibility of creating a reliable FNS cooling system with a liquid metal heat carrier problematic. There exists a reasonable alternative to liquid metals in FNS, molten salts, namely, the melt of lithium and beryllium fluorides (Flibe) and the melt of fluorides of alkali metals (Flinak). Molten salts, however, are poorly studied media, and their application requires detailed scientific substantiation. We analyze the modern state of the art of studies in this field. Our contribution is to answer the following question: whether above-mentioned extremely dangerous regimes of MHD heat exchange detected in liquid metals can exist in molten salts. Experiments and numerical simulation were performed in order to answer this question. The experimental test facility represents a water circuit, since water (or water with additions for increasing its electrical conduction) is a convenient medium for laboratory simulation of salt heat exchange in FNS conditions. Local heat transfer coefficients along the heated tube, three-dimensional (along the length and in the cross section, including the viscous sublayer) fields of averaged temperature and temperature pulsations are studied. The probe method for measurements in a flow is described in detail. Experimental data are designated for verification of codes simulating heat exchange of molten salts.

Cation and anion dependence of stable geometries and stabilization energies of alkali metal cation complexes with FSA(-), FTA(-), and TFSA(-) anions: relationship with physicochemical properties of molten salts.

PubMed

Tsuzuki, Seiji; Kubota, Keigo; Matsumoto, Hajime

2013-12-19

Stable geometries and stabilization energies (Eform) of the alkali metal complexes with bis(fluorosulfonyl)amide, (fluorosulfonyl)(trifluoromethylslufonyl)amide and bis(trifluoromethylsulfonyl)amide (FSA(-), FTA(-) and TFSA(-)) were studied by ab initio molecular orbital calculations. The FSA(-) complexes prefer the bidentate structures in which two oxygen atoms of two SO2 groups have contact with the metal cation. The FTA(-) and TFSA(-) complexes with Li(+) and Na(+) prefer the bidentate structures, while the FTA(-) and TFSA(-) complexes with Cs(+) prefer tridentate structures in which the metal cation has contact with two oxygen atoms of an SO2 group and one oxygen atom of another SO2 group. The two structures are nearly isoenergetic in the FTA(-) and TFSA(-) complexes with K(+) and Rb(+). The magnitude of Eform depends on the alkali metal cation significantly. The Eform calculated for the most stable TFSA(-) complexes with Li(+), Na(+), K(+), Rb(+) and Cs(+) cations at the MP2/6-311G** level are -137.2, -110.5, -101.1, -89.6, and -84.1 kcal/mol, respectively. The viscosity and ionic conductivity of the alkali TFSA molten salts have strong correlation with the magnitude of the attraction. The viscosity increases and the ionic conductivity decreases with the increase of the attraction. The melting points of the alkali TFSA and alkali BETA molten salts also have correlation with the magnitude of the Eform, which strongly suggests that the magnitude of the attraction play important roles in determining the melting points of these molten salts. The anion dependence of the Eform calculated for the complexes is small (less than 2.9 kcal/mol). This shows that the magnitude of the attraction is not the cause of the low melting points of alkali FTA molten salts compared with those of corresponding alkali TFSA molten salts. The electrostatic interactions are the major source of the attraction in the complexes. The electrostatic energies for the most stable TFSA(-) complexes with the five alkali metal cations are -140.3, -119.4, -104.1, -96.9, and -91.1 kcal/mol, respectively. The induction interactions also contribute to the attraction. In particular, the induction interactions are large in the Li(+) complexes. The induction energies for the five complexes are -46.6, -25.2, -17.5, -13.3, and -10.4 kcal/mol, respectively.

Development of a High Ionization Efficiency Molten Glass Ion Emitter for TIMS

NASA Astrophysics Data System (ADS)

Cheversia, M. B.; Farmer, G.; Koval, C.; David, D.

2006-12-01

Thermal ionization mass spectrometry (TIMS) remains the method of choice for many high precision isotope ratio determinations but is handicapped by the use of low efficiency ion emitters. For example, ionization efficiencies from molten glass emitters (Si-gel) used for such elements as Pb, Cr, Ru, and Ag are in the range of 0.05-2%, which limits the sample size and the precision to which isotope ratio determinations for these elements can be made. Our aim is to improve the ionization efficiency of the molten glass ion emitter using electrochemical methods. This work builds on recent observations indicating that many metals doped in borosilicate glasses (eg. Bi, Ag), are emitted from the liquid glass (in vacuo) primarily as the neutral metal atom. Our goal is to increase the proportion of singly charged metal atoms in metal-doped molten glasses via oxidation induced by electrochemical methods and to assess whether such in situ oxidation of metal atoms leads to an increase in emitted metal ions. Our experiments are performed in a vacuum chamber that mimics conditions in the sample chamber of the TIMS. A borosilicate glass sample is placed in a miniature ceramic crucible. The crucible contains working and reference Pt electrodes, and a Pt thermocouple. The entire apparatus is wrapped with a resistively heated Ta wire until temperatures in the glass reach approximately 1400°C, to ensure that the glass is molten. By this method, we have produced simple cyclic voltammograms that suggest that over a 100°C temperature range, the borosilicate glass undergoes a transition from resistive behavior as a solid, to a conductive electrolyte, as a molten liquid glass, as expected. The change is evident as an order of magnitude decrease in resistivity of the glass, as interpreted from the voltammograms. The voltammograms produced for the pure borosilicate glasses represent the baseline against which we will compare the electrochemical characteristics of Pb doped glasses. These experiments are currently underway and are designed to determine the speciation of lead in the glass, and to determine the voltages required to induce cathodic currents in the glass corresponding to ionization to Pb+ and Pb2+. By generating a cathodic current and an increased concentration of the oxidized species, we hope to ultimately generate a higher intensity ion beam, higher ionization efficiency for low efficiency elements, and higher precision analyses on small sample sizes for the TIMS.

The mechanism of liquid metal jet formation in the cathode spot of vacuum arc discharge

NASA Astrophysics Data System (ADS)

Gashkov, M. A.; Zubarev, N. M.; Mesyats, G. A.; Uimanov, I. V.

2016-08-01

We have theoretically studied the dynamics of molten metal during crater formation in the cathode spot of vacuum arc discharge. At the initial stage, a liquid-metal ridge is formed around the crater. This process has been numerically simulated in the framework of the two-dimensional axisymmetric heat and mass transfer problem in the approximation of viscous incompressible liquid. At a more developed stage, the motion of liquid metal loses axial symmetry, which corresponds to a tendency toward jet formation. The development of azimuthal instabilities of the ridge is analyzed in terms of dispersion relations for surface waves. It is shown that maximum increments correspond to instability of the Rayleigh-Plateau type. Estimations of the time of formation of liquid metal jets and their probable number are obtained.

Method and apparatus for fabricating a composite structure consisting of a filamentary material in a metal matrix

DOEpatents

Banker, J.G.; Anderson, R.C.

1975-10-21

A method and apparatus are provided for preparing a composite structure consisting of filamentary material within a metal matrix. The method is practiced by the steps of confining the metal for forming the matrix in a first chamber, heating the confined metal to a temperature adequate to effect melting thereof, introducing a stream of inert gas into the chamber for pressurizing the atmosphere in the chamber to a pressure greater than atmospheric pressure, confining the filamentary material in a second chamber, heating the confined filamentary material to a temperature less than the melting temperature of the metal, evacuating the second chamber to provide an atmosphere therein at a pressure, placing the second chamber in registry with the first chamber to provide for the forced flow of the molten metal into the second chamber to effect infiltration of the filamentary material with the molten metal, and thereafter cooling the metal infiltrated-filamentary material to form said composite structure.

2D modeling of direct laser metal deposition process using a finite particle method

NASA Astrophysics Data System (ADS)

Anedaf, T.; Abbès, B.; Abbès, F.; Li, Y. M.

2018-05-01

Direct laser metal deposition is one of the material additive manufacturing processes used to produce complex metallic parts. A thorough understanding of the underlying physical phenomena is required to obtain a high-quality parts. In this work, a mathematical model is presented to simulate the coaxial laser direct deposition process tacking into account of mass addition, heat transfer, and fluid flow with free surface and melting. The fluid flow in the melt pool together with mass and energy balances are solved using the Computational Fluid Dynamics (CFD) software NOGRID-points, based on the meshless Finite Pointset Method (FPM). The basis of the computations is a point cloud, which represents the continuum fluid domain. Each finite point carries all fluid information (density, velocity, pressure and temperature). The dynamic shape of the molten zone is explicitly described by the point cloud. The proposed model is used to simulate a single layer cladding.

Formation of liquid-metal jets in a vacuum arc cathode spot: Analogy with drop impact on a solid surface

NASA Astrophysics Data System (ADS)

Gashkov, M. A.; Zubarev, N. M.

2018-01-01

Conditions of the liquid-metal jets formation in a cathode spot of a vacuum arc discharge are studied. Our consideration is based on the analogy between the processes, occurring in the liquid phase of the cathode spot, and the processes, accompanying a liquid drop impact on a flat solid surface. In the latter case there exists a wide variety of experimental data on the conditions under which the spreading regime of fluid motion (i.e., without formation of jets and secondary droplets) changes into the splashing one. In the present work, using the hydrodynamic similarity principle (processes in geometrically similar systems will proceed similarly when their Weber and Reynolds numbers coincide), criteria for molten metal splashing are formulated for different materials of the cathode. They are compared with the experimental data on the threshold conditions for vacuum arc burning.

Monolith electroplating process

DOEpatents

Agarrwal, Rajev R.

2001-01-01

An electroplating process for preparing a monolith metal layer over a polycrystalline base metal and the plated monolith product. A monolith layer has a variable thickness of one crystal. The process is typically carried in molten salts electrolytes, such as the halide salts under an inert atmosphere at an elevated temperature, and over deposition time periods and film thickness sufficient to sinter and recrystallize completely the nucleating metal particles into one single crystal or crystals having very large grains. In the process, a close-packed film of submicron particle (20) is formed on a suitable substrate at an elevated temperature. The temperature has the significance of annealing particles as they are formed, and substrates on which the particles can populate are desirable. As the packed bed thickens, the submicron particles develop necks (21) and as they merge into each other shrinkage (22) occurs. Then as micropores also close (23) by surface tension, metal density is reached and the film consists of unstable metal grain (24) that at high enough temperature recrystallize (25) and recrystallized grains grow into an annealed single crystal over the electroplating time span. While cadmium was used in the experimental work, other soft metals may be used.

Investigation of Dynamic Oxygen Adsorption in Molten Solder Jetting Technology

NASA Technical Reports Server (NTRS)

Megaridis, Constantine M.; Bellizia, Giulio; McNallan, Michael; Wallace, David B.

2003-01-01

Surface tension forces play a critical role in fluid dynamic phenomena that are important in materials processing. The surface tension of liquid metals has been shown to be very susceptible to small amounts of adsorbed oxygen. Consequently, the kinetics of oxygen adsorption can influence the capillary breakup of liquid-metal jets targeted for use in electronics assembly applications, where low-melting-point metals (such as tin-containing solders) are utilized as an attachment material for mounting of electronic components to substrates. By interpreting values of surface tension measured at various surface ages, adsorption and diffusion rates of oxygen on the surface of the melt can be estimated. This research program investigates the adsorption kinetics of oxygen on the surface of an atomizing molten-metal jet. A novel oscillating capillary jet method has been developed for the measurement of dynamic surface tension of liquids, and in particular, metal melts which are susceptible to rapid surface degradation caused by oxygen adsorption. The experimental technique captures the evolution of jet swells and necks continuously along the jet propagation axis and is used in conjunction with an existing linear, axisymmetric, constant-property model to determine the variation of the instability growth rate, and, in turn, surface tension of the liquid as a function of surface age measured from the exit orifice. The conditions investigated so far focus on a time window of 2-4ms from the jet orifice. The surface properties of the eutectic 63%Sn-37%Pb solder alloy have been investigated in terms of their variation due to O2 adsorption from a N2 atmosphere containing controlled amounts of oxygen (from 8 ppm to 1000 ppm). The method performed well for situations where the oxygen adsorption was low in that time window. The value of surface tension for the 63Sn-37Pb solder in pure nitrogen was found to be 0.49 N/m, in good agreement with previously published work. A characteristic time of O(1ms) or less was determined for the molten-metal surface to be saturated by oxygen at 1000 ppm concentration in N2.

Numerical Modeling of Inclusion Behavior in Liquid Metal Processing

NASA Astrophysics Data System (ADS)

Bellot, Jean-Pierre; Descotes, Vincent; Jardy, Alain

2013-09-01

Thermomechanical performance of metallic alloys is directly related to the metal cleanliness that has always been a challenge for metallurgists. During liquid metal processing, particles can grow or decrease in size either by mass transfer with the liquid phase or by agglomeration/fragmentation mechanisms. As a function of numerical density of inclusions and of the hydrodynamics of the reactor, different numerical modeling approaches are proposed; in the case of an isolated particle, the Lagrangian technique coupled with a dissolution model is applied, whereas in the opposite case of large inclusion phase concentration, the population balance equation must be solved. Three examples of numerical modeling studies achieved at Institut Jean Lamour are discussed. They illustrate the application of the Lagrangian technique (for isolated exogenous inclusion in titanium bath) and the Eulerian technique without or with the aggregation process: for precipitation and growing of inclusions at the solidification front of a Maraging steel, and for endogenous inclusions in the molten steel bath of a gas-stirred ladle, respectively.

Sulfidation treatment of molten incineration fly ashes with Na2S for zinc, lead and copper resource recovery.

PubMed

Kuchar, D; Fukuta, T; Onyango, M S; Matsuda, H

2007-04-01

The present study focuses on the conversion of heavy metals involved in molten incineration fly ashes to metal sulfides which could be thereafter separated by flotation. The sulfidation treatment was carried out for five molten incineration fly ashes (Fly ash-A to Fly ash-E) by contacting each fly ash with Na(2)S solution for a period of 10 min to 6h. The initial molar ratio of S(2-) to Me(2+) was adjusted to 1.20. The conversion of heavy metals to metal sulfides was evaluated by measuring the S(2-) residual concentrations using an ion selective electrode. The formation of metal sulfides was studied by XRD and SEM-EDS analyses. In the case of Fly ash-A to Fly ash-D, more than 79% of heavy metals of zinc, lead and copper was converted to metal sulfides within the contacting period of 0.5h owing to a fast conversion of metal chlorides to metal sulfides. By contrast, the conversion of about 35% was achieved for Fly ash-E within the same contacting period, which was attributed to a high content of metal oxides. Further, the S(2-) to Me(2+) molar ratio was reduced to 1.00 to minimize Na(2)S consumption and the conversions obtained within the contacting period of 0.5h varied from 76% for Fly ash-D to 91% for Fly ash-C. Finally, soluble salts such as NaCl and KCl were removed during the sulfidation treatment, which brought about a significant enrichment in metals content by a factor varying from 1.5 for Fly ash-D to 4.9 for Fly ash-A.

Intelligent Sensors for Atomization Processing of Molten Metals and Alloys

DTIC Science & Technology

1988-06-01

20ff. 12. Hirleman, Dan E. Particle Sizing by Optical , Nonimaging Techniques. Liquid Particle Size Measurement Techniques, ASTM, 1984, pp. 35ff. 13...sensors are based on electric, electromagnetic or optical principles, the latter being most developed in fields obviously related to atomization. Optical ...beams to observe various interference, diffraction, and heterodyning effects, and to observe, with high signal-to-noise ratio, even weak optical

APPARATUS AND METHOD FOR INJECTION CASTING

DOEpatents

Shuck, A.B.

1960-09-13

S>A single-chamber metal casting apparatus is described wherein molten metal in a vertically movable container can be brought directly into contact with molds. By increasing the gas pressure within the chamber the metal is forced upward into the molds.

Direct oxygen removal technique for recycling titanium using molten MgCl2 salt.

PubMed

Okabe, Toru H; Hamanaka, Yuki; Taninouchi, Yu-Ki

2016-08-15

Deoxidation of Ti, or direct removal of O dissolved in metallic Ti, is known to be extremely difficult when Mg is used as the deoxidizing agent. This difficulty arises because the chemical potential of O2, pO2, under Mg/MgO equilibrium is high (approximately 10(-41) atm at 1200 K) and is equivalent to that of Ti containing ∼2 mass% O at 1200 K. Therefore, when deoxidizing Ti to the commercial level of high-grade pure Ti (below 0.05 mass% O) using an Mg reductant at 1200 K, the activity of the reaction product MgO (aMgO) must be decreased to below ∼0.025, which is difficult in practice. In this study, the removal of O in Ti in molten MgCl2 salt using an electrochemical technique was examined at ∼1173 K with the objective of obtaining Ti containing less than 0.05 mass% O. Ti samples and graphite electrodes immersed in molten MgCl2 served as the cathode and anode, respectively. A constant voltage was applied between the electrodes using an external DC source. Molten MgCl2 was employed to produce the deoxidizing agent Mg and to facilitate deoxidation of Ti by decreasing the activity of the reaction product MgO. By applying a voltage of approximately 3.1 V between the electrodes, the chemical potential of Mg in the molten MgCl2 was increased at the surface of the Ti cathode, and the Ti samples were deoxidized. The resulting O species, mainly formed O(2-) dissolved in the molten MgCl2, was removed from the molten salt by reacting with the C anode to form CO (or CO2) gas. Ti wires containing 0.12 mass% O were deoxidized to less than 0.02 mass% O. In some cases, the O concentration in the Ti samples was reduced to the level of 0.01 mass%, which cannot be accomplished using the conventional Kroll process. The possible application of this deoxidation technique to practical industrial recycling processes is discussed.

Recovery of protactinium from molten fluoride nuclear fuel compositions

DOEpatents

Baes, C.F. Jr.; Bamberger, C.; Ross, R.G.

1973-12-25

A method is provided for separating protactinium from a molten fluonlde salt composition consisting essentially of at least one alkali and alkaline earth metal fluoride and at least one soluble fluoride of uranium or thorium which comprises oxidizing the protactinium in said composition to the + 5 oxidation state and contacting said composition with an oxide selected from the group consisting of an alkali metal oxide, an alkaline earth oxide, thorium oxide, and uranium oxide, and thereafter isolating the resultant insoluble protactinium oxide product from said composition. (Official Gazette)

Synthesis of high T.sub.C superconducting coatings and patterns by melt writing and oxidation of metallic precursor alloys

DOEpatents

Gao, Wei; Vander Sande, John B.

1998-01-01

A method is provided for fabrication of superconducting oxides and superconducting oxide composites and for joining superconductors to other materials. A coating of a molten alloy containing the metallic elements of the oxide is applied to a substrate surface and oxidized to form the superconducting oxide. A material can be contacted to the molten alloy which is subsequently oxidized joining the material to the resulting superconducting oxide coating. Substrates of varied composition and shape can be coated or joined by this method.

Synthesis of high {Tc} superconducting coatings and patterns by melt writing and oxidation of metallic precursor alloys

DOEpatents

Gao, W.; Vander Sande, J.B.

1998-07-28

A method is provided for fabrication of superconducting oxides and superconducting oxide composites and for joining superconductors to other materials. A coating of a molten alloy containing the metallic elements of the oxide is applied to a substrate surface and oxidized to form the superconducting oxide. A material can be contacted to the molten alloy which is subsequently oxidized joining the material to the resulting superconducting oxide coating. Substrates of varied composition and shape can be coated or joined by this method. 5 figs.

Latent energy storage with salt and metal mixtures for solar dynamic applications

NASA Technical Reports Server (NTRS)

Crane, R. A.; Konstantinou, K. S.

1988-01-01

This paper examines three design alternatives for the development of a solar dynamic heat receiver as applied to power systems operating in low earth orbit. These include a base line design used for comparison in ongoing NASA studies, a system incorporating a salt energy storage system with the salt dispersed within a metal mesh and a hybrid system incorporating both a molten salt and molten metal for energy storage. Based on a typical low earth orbit condition, designs are developed and compared to determine the effect of resultant conductivity, heat capacity and heat of fusion on system size, weight, temperature gradients, cycle turbine inlet temperature and material utilization.

Production of Oxygen from Lunar Regolith by Molten Oxide Electrolysis

NASA Technical Reports Server (NTRS)

Curreri, Peter A.

2009-01-01

This paper describes the use of the molten oxide electrolysis (MOE) process for the extraction of oxygen for life support and propellant, and silicon and metallic elements for use in fabrication on the Moon. The Moon is rich in mineral resources, but it is almost devoid of chemical reducing agents, therefore, molten oxide electrolysis is ideal for extraction, since the electron is the only practical reducing agent. MOE has several advantages over other extraction methods. First, electrolytic processing offers uncommon versatility in its insensitivity to feedstock composition. Secondly, oxide melts boast the twin key attributes of highest solubilizing capacity for regolith and lowest volatility of any candidate electrolytes. The former is critical in ensuring high productivity since cell current is limited by reactant solubility, while the latter simplifies cell design by obviating the need for a gas-tight reactor to contain evaporation losses as would be the case with a gas or liquid phase fluoride reagent operating at such high temperatures. Alternatively, MOE requires no import of consumable reagents (e.g. fluorine and carbon) as other processes do, and does not rely on interfacing multiple processes to obtain refined products. Electrolytic processing has the advantage of selectivity of reaction in the presence of a multi-component feed. Products from lunar regolith can be extracted in sequence according to the stabilities of their oxides as expressed by the values of the free energy of oxide formation (e.g. chromium, manganese, Fe, Si, Ti, Al, magnesium, and calcium). Previous work has demonstrated the viability of producing Fe and oxygen from oxide mixtures similar in composition to lunar regolith by molten oxide electrolysis (electrowinning), also called magma electrolysis having shown electrolytic extraction of Si from regolith simulant. This paper describes recent advances in demonstrating the MOE process by a joint project with participation by NASA KSC and MSFC, and Ohio State University and MIT. Progress in measuring cell efficiency for oxygen production, development of non reacting electrodes, and cell feeding and withdrawal will be discussed.

PURIFICATION OF URANIUM FUELS

DOEpatents

Niedrach, L.W.; Glamm, A.C.

1959-09-01

An electrolytic process of refining or decontaminating uranium is presented. The impure uranium is made the anode of an electrolytic cell. The molten salt electrolyte of this cell comprises a uranium halide such as UF/sub 4/ or UCl/sub 3/ and an alkaline earth metal halide such as CaCl/sub 2/, BaF/sub 2/, or BaCl/sub 2/. The cathode of the cell is a metal such as Mn, Cr, Co, Fe, or Ni which forms a low melting eutectic with U. The cell is operated at a temperature below the melting point of U. In operation the electrodeposited uranium becomes alloyed with the metal of the cathode, and the low melting alloy thus formed drips from the cathode.

Application of Molten Salt Reactor Technology to Nuclear Electric Propulsion Mission

NASA Technical Reports Server (NTRS)

Patton, Bruce; Sorensen, Kirk; Rodgers, Stephen L. (Technical Monitor)

2002-01-01

Nuclear electric propulsion (NEP) and planetary surface power missions require reactors that are lightweight, operationally robust, and scalable in power for widely varying scientific mission objectives. Molten salt reactor technology meets all of these requirements and offers an interesting alternative to traditional gas cooled, liquid metal, and heat pipe space reactors.

49 CFR 174.86 - Maximum allowable operating speed.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 49 Transportation 2 2011-10-01 2011-10-01 false Maximum allowable operating speed. 174.86 Section... operating speed. (a) For molten metals and molten glass shipped in packagings other than those prescribed in § 173.247 of this subchapter, the maximum allowable operating speed may not exceed 24 km/hour (15 mph...

49 CFR 174.86 - Maximum allowable operating speed.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 49 Transportation 2 2010-10-01 2010-10-01 false Maximum allowable operating speed. 174.86 Section... operating speed. (a) For molten metals and molten glass shipped in packagings other than those prescribed in § 173.247 of this subchapter, the maximum allowable operating speed may not exceed 24 km/hour (15 mph...

Candidate molten salt investigation for an accelerator driven subcritical core

NASA Astrophysics Data System (ADS)

Sooby, E.; Baty, A.; Beneš, O.; McIntyre, P.; Pogue, N.; Salanne, M.; Sattarov, A.

2013-09-01

We report a design for accelerator-driven subcritical fission in a molten salt core (ADSMS) that utilizes a fuel salt composed of NaCl and transuranic (TRU) chlorides. The ADSMS core is designed for fast neutronics (28% of neutrons >1 MeV) to optimize TRU destruction. The choice of a NaCl-based salt offers benefits for corrosion, operating temperature, and actinide solubility as compared with LiF-based fuel salts. A molecular dynamics (MD) code has been used to estimate properties of the molten salt system which are important for ADSMS design but have never been measured experimentally. Results from the MD studies are reported. Experimental measurements of fuel salt properties and studies of corrosion and radiation damage on candidate metals for the core vessel are anticipated. A special thanks is due to Prof. Paul Madden for introducing the ADSMS group to the concept of using the molten salt as the spallation target, rather than a conventional heavy metal spallation target. This feature helps to optimize this core as a Pu/TRU burner.

Diffusion welded nonconsumable electrode assembly and use thereof for electrolytic production of metals and silicon

DOEpatents

Byrne, Stephen C.; Vasudevan, Asuri K.

1984-01-01

A nonconsumable electrode assembly suitable for use in the production of metal by electrolytic reduction of a metal compound dissolved in a molten salt, the assembly comprising a metal conductor diffusion welded to a portion of a ceramic electrode body having a level of free metal or metal alloy sufficient to effect a metal bond.

Cooling Rate Determination in Additively Manufactured Aluminum Alloy 2219

NASA Astrophysics Data System (ADS)

Brice, Craig A.; Dennis, Noah

2015-05-01

Metallic additive manufacturing processes generally utilize a conduction mode, welding-type approach to create beads of deposited material that can be arranged into a three-dimensional structure. As with welding, the cooling rates in the molten pool are relatively rapid compared to traditional casting techniques. Determination of the cooling rate in the molten pool is critical for predicting the solidified microstructure and resultant properties. In this experiment, wire-fed electron beam additive manufacturing was used to melt aluminum alloy 2219 under different thermal boundary conditions. The dendrite arm spacing was measured in the remelted material, and this information was used to estimate cooling rates in the molten pool based on established empirical relationships. The results showed that the thermal boundary conditions have a significant effect on the resulting cooling rate in the molten pool. When thermal conduction is limited due to a small thermal sink, the dendrite arm spacing varies between 15 and 35 µm. When thermal conduction is active, the dendrite arm spacing varies between 6 and 12 µm. This range of dendrite arm spacing implies cooling rates ranging from 5 to 350 K/s. Cooling rates can vary greatly as thermal conditions change during deposition. A cooling rate at the higher end of the range could lead to significant deviation from microstructural equilibrium during solidification.

Metal spray apparatus with a U-shaped electric inlet gas heater and a one-piece electric heater surrounding a nozzle

DOEpatents

Glovan, Ronald J.; Tierney, John C.; McLean, Leroy L.; Johnson, Lawrence L.; Verbael, David J.

1995-01-01

An electrically heated metal spray apparatus is provided with a supersonic nozzle. Molten metal is injected into a gas stream flowing through the nozzle under pressure. By varying the pressure of the injected metal, the droplet can be made in various selected sizes with each selected size having a high degree of size uniformity. A unique one piece graphite heater provides easily controlled uniformity of temperature in the nozzle and an attached tundish which holds the pressurized molten metal. A unique U-shaped gas heater provides extremely hot inlet gas temperatures to the nozzle. A particularly useful application of the spray apparatus is coating of threads of a fastener with a shape memory alloy. This permits a fastener to be easily inserted and removed but provides for a secure locking of the fastener in high temperature environments.