Metallurgy Commons^™

Impurity Behavior In Cast Copper Anodes: Implications For Electrorefining In A Circular Economy, Agustin Morales-Aragon, Daniel Sánchez-Rodas, Guillermo Ríos, Michael S. Moats

Materials Science and Engineering Faculty Research & Creative Works

The behavior of impurities in cast copper was investigated to simulate production with increased utilization of secondary sources within the framework of a circular economy. The incorporation of impurities, particularly Ni, Sn, and Sb, from recycled Cu may significantly impact the electrorefining process. In this study, commercial anodes were doped with Ni, Sn, and Sb concentrations of 2500–6500 g/t, 300–900 g/t, and 450–950 g/t, respectively. Anode concentrations of Pb and Bi were maintained at 1000 g/t and 350 g/t, respectively. As concentrations were examined at two levels, 860 or 1700 g/t, depending on the commercial anode used to create the …

Nickel Superalloy Composition And Process Optimization For Weldability, Cost, And Strength, Sophie A. Mehl

Dissertations, Master's Theses and Master's Reports

To advance sustainability efforts, electric power plants have reduced specific carbon dioxide emissions by increasing operating temperatures and pressures to improve power generation efficiency. The latest improvements are utilized in advanced ultra-supercritical power generation. To meet these operating conditions, nickel superalloys are used in the highest temperature components; however, they are expensive and present weldability challenges. This project aims to experimentally optimize a nickel superalloy to improve material weldability and decrease cost without compromising strength. Three optimized compositions were developed, and their microstructures and mechanical properties were compared to Nimonic 263, a common nickel superalloy in electric power plants. The …

Machine Learning Strategies For Potential Development In High-Entropy Driven Nickel-Based Superalloys, Marium Mostafiz Mou

Graduate Theses/Dissertations

In this study, I developed Deep Learning interatomic potentials to model a multi-phase and multi-component system of Ni-based Superalloys. The system has up to three major phase constituents, namely Gamma, Gamma Prime, and Transition-metal rich Carbide. I utilized invariant scalar-based and/or equivariant, tensor-based neural network (NN) approach as implemented in DEEPMD, NEQUIP/ALLEGRO codes, respectively, and Moment Tensor Potential (MTP). For the training and validation sets, I employed the ab-initio molecular dynamics (AIMD) trajectory results and ground state DFT calculations, including the energy, force, and virial database from highly diverse compositions, temperatures, and pressures following a “High Entropy Strategy.” The Deep …

Functionally Magnetic Gradient Copper-Nickel Material Fabricated Via Directed Energy Deposition, Vy Tran Phuong Nguyen

Graduate Theses, Dissertations, and Problem Reports (ETD)

Functionally gradient materials (FGMs) of CuSn10 and Inconel 718 were fabricated via a hybrid directed energy deposition (DED) system. The objective of the present thesis is to determine the feasibility of manufacturing CuSn10 and Inconel 718 FGMs via DED and investigate the physical and mechanical properties and the microstructures of the resulting FGMs. The physical tests comprised of conductivity and Seebeck coefficient measurements. The microstructure analysis and mechanical testing include microscopic imaging, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and hardness test. In addition, compressive strength test was performed to analyze the interface bonding behaviors.

Martensitic And Inter-Martensitic Transformations In Magnetocaloric Ni2.15mn0.85ga Heusler Alloy, A. Madiligama, P. Ari-Gur, Y, Ren, V, Shavrov, Y. Ge, J. George, I. Musabirov, V. Koledov

Mechanical and Aerospace Engineering Faculty Publications

The entropy changes of successive martensitic phase transformations in Ni-Mn-Ga Heusler alloys can be utilized to realize enhanced magnetocaloric properties. A detailed study of phase transformations of one such alloy, Ni2.15Mn0.85Ga, (ΔQ = 4900 J/kg at 343 K, under 140 kOe), is reported here. Upon cooling, the paramagnetic cubic (L21) austenitic phase transforms into a ferromagnetic 7M modulated monoclinic martensitic phase. This phase is stable in a narrow temperature range, and upon further cooling, transforms into a non-modulated ferromagnetic tetragonal (L10) phase. The separation between the equilibrium temperatures of the austenitic and tetragonal martensitic phases is only ~50 K. The …

Role Of Eta Phase Evolution On Creep Properties Of Nickel Base Superalloys Used In Advanced Electric Power Generation Plants, Ninad Mohale

Dissertations, Master's Theses and Master's Reports

Advanced fossil energy power generation plants require materials that withstand high temperatures and corrosive environments. One such material that is used in steam turbines is Nimonic 263. It is a nickel-base superalloy that is principally strengthened by gamma primephase (Ni₃(Ti, Al)) and has an L1₂structure. At extended times and at turbine operating temperatures however, eta (Ni₃Ti) phase is known to form at the expense of gamma prime. Eta has a complex DO₂₄structure and is the stable phase between 750°C and 900°C, but with slow kinetics of formation. Little is understood about eta …

Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator

Materials Engineering

PCC Structurals, an industry leader in superalloy investment castings, has observed inconsistencies in the stress rupture performance of polycrystalline nickel-based superalloy PWA 1455. PCC has changed their casting parameters to reduce the thermal gradient during cooling but have been unable to correlate these changes with an increase in stress rupture elongation. Metallographic examination of past samples indicated microstructures composed of non- equiaxed dendritic grains with mean diameter of .021 inches along the test axis. A similar study on polycrystalline superalloys has indicated that excessive superheat temperatures above the liquidus can result in large grains identical to those observed, limiting the …

Development Of Oxide-Dispersion-Strengthened Nickel-Based Super Alloy Powders For Additive Manufacturing, Sizhe Huang

Graduate Theses, Dissertations, and Problem Reports (ETD)

Oxide-Dispersion-Strengthened (ODS) Nickel-Based superalloy has been drawn a huge attention and developed with good oxidation resistance, corrosion resistance and high creep strength. It has been considered as critical materials for Additive Manufacturing (AM). The quality and the efficiency of fabrication methods of ODS limits the performance of itself on AM. The development of new type of ODS, new methodologies and evaluation techniques are required if the enhanced quality of ODS and enhanced efficiency of fabrication are to be achieved. Of the current fabrication techniques for AM, Gas Atomization (GA) is widely used since they can generate spherical powders with high …

Development Of Low Cost Braze Alloys For Aerospace Applications, Alyssa M. Elliott, Sandy Babich, Blake Whitmee

Materials Engineering

Non-precious metal braze alloys can help lower the cost of brazing, which is a commonly-used joining process in the aerospace industry. A-286, a stainless steel superalloy, and Inconel© 718, a nickel-based superalloy, are both commonly used alloys at Aerojet Rocketdyne. Both alloys were brazed into butt joints using nickel-based braze alloys: AMS 4776, 4777, and 4778. The brazed samples were machined into a modified version of the ASTM E8 subsize specimen samples and tensile tested to compare the strength and calculated elongation of the brazed samples to the base metals’ properties. All of the brazed samples fractured at the joint, …

Dissimilar Metal Weld Variability Due To Lot Differences In Nitinol/ Stainless Steel Interface, Matthew R. Rudow

Materials Engineering

Abstract

An experiment was conducted to determine and reduce the causes of variation between a 304 Stainless Steel and super elastic Nickel Titanium dissimilar metal weld. Six factors were established to understand the cause of variation: perpendicularity, final grind, surface finish, weld force, weld pulse duration, and alignment. Using a rotational test with an air piston break pressures were established and charted in Minitab to identify trends. It was shown that weld force and weld pulse duration were the two factors that had the most influence on break strength. This data also showed that higher strength groups had less variability. …

Development Of Nanostructure Based Corrosion-Barrier Coatings On Steel For Transmutation Applications, Biswajit Das

Transmutation Sciences Materials (TRP)

Advanced transmutation systems require structural materials that are able to withstand high neutron fluxes, high thermal cycling, and high resistance to chemical corrosion. The current candidate materials for such structures are ferritic and ferritic-martensitic steels due to their strong resistance to swelling, good microstructural stability under irradiation, and the retention of adequate ductility at typical reactor operating temperatures.

In parallel, lead-bismuth eutectic (LBE) has emerged as a potential spallation target material for efficient production of neutrons, as well as a coolant in the accelerator system. While LBE has excellent properties as a nuclear coolant, it is also highly corrosive to …

Corrosion Barrier Development For Lbe Corrosion Resistance: Quarterly Report (April 2006), Biswajit Das

Transmutation Sciences Materials (TRP)

As reported in the last quarterly report, synthesis of Cr nanowires was found to be problematic in terms of uniform coverage. Hence Ni was identified as the alternative metal to form the nanowires. The purpose of the metal nanowires is to provide structural integrity to the nanoporous alumina, as well as a second defense mechanism against corrosion by oxidizing in case the top alumina layer is compromised. Nickel was selected due to its established electrochemical synthesis procedure. While Ni can provide very good structural integrity to the porous alumina, one potential problem is its higher dissolution rate in LBE. However, …

Experimental Investigation Of Steel Corrosion In Lead Bismuth Eutectic (Lbe): Characterization, Species Identification, And Chemical Reactions, John Farley, Dale L. Perry, Allen L. Johnson

Transmutation Sciences Materials (TRP)

The goal of the present research is to achieve a basic understanding of corrosion of steels by Lead Bismuth Eutectic (LBE). Liquid LBE is under consideration in the transmuter as both a spallation target and as a blanket coolant. There have been previous studies of LBE, especially by the Russians, who have over 80 reactor-years experience with LBE coolant in their Alpha-class submarine reactors. The Russians found that the presence of small amounts (ppm) of oxygen in the LBE significantly reduced corrosion. However, a fundamental understanding and verification of its role in the corrosion of steels is still very incomplete. …

Third Quarter Report, Covering January Through March 2002, John Farley

Transmutation Sciences Materials (TRP)

Progress from June 2001-November 2001 was presented at the winter meeting of the American Nuclear Society in Reno (November 12-15, 2001), and incorporated into a refereed conference proceeding. A copy of the refereed conference proceeding has been provided to Tony Hechanova. In brief, the paper described the new program to examine the corrosive effects of lead-bismuth eutectic (LBE) on steels. We employed various types of surface studies (Scanning Electron Microscope [SEM], and X-ray Photoelectron Spectrometry [XPS]) to examine steel samples that had been exposed to LBE for various lengths of time at various temperatures. The goal is to understand the …

Experimental Investigation Of Steel Corrosion In Lead Bismuth Eutectic (Lbe): Characterization, Species Identification, And Chemical Reactions, John Farley, Dale L. Perry, Allen L. Johnson

Transmutation Sciences Materials (TRP)

The goal of the present research is to achieve a basic understanding of corrosion of steels by Lead Bismuth Eutectic (LBE). Liquid LBE is under consideration in the transmuter as both a spallation target and as a blanket coolant. There have been previous studies of LBE, especially by the Russians, who have over 80 reactor-years experience with LBE coolant in their Alpha-class submarine reactors. However, a fundamental understanding and verification of its role in the corrosion of steels is still very incomplete. We have begun a program of post-experiment testing and analysis on steel samples that have been in intimate …

Analysis Of Corrosion Of Steel By Lead Bismuth Eutectic, John Farley, Dale L. Perry

Transmutation Sciences Materials (TRP)

We examined stainless samples that were exposed to LBE in experiments conducted by the Russians, under contract to Los Alamos. We examined both corroded and uncorroded samples using the Scanning Electron Microscope (SEM), the Energy Dispersive X-Ray (EDAX) Spectroscopy, and the X-ray Photoelectron Spectrometer (XPS). We found that the surface of the corroded sample is covered by oxygen-containing compounds, presumably mostly iron oxide. In samples exposed for shorter times or lower temperatures, we found that some areas were covered by an oxide layer, and some areas was uncovered. We found that the level of Cr in the uncovered area is …

Stress-Induced Martensite Transformation In An Alloy Of The Copper-Aluminum-Nickel System, Gary D. Alexander

Bachelors Theses and Reports, 1928 - 1970

It was intended that the alloy be thoroughly investigated for martensite transformation that would make the alloy "super-elastic," but due to the many difficulties that arose this was not possible. Attempts to grow a single crystal from the cast alloy were not successful because of the difficulties that were encountered with the Kanthal resistance furnace (referred to later). Consequently, the growing of the single crystal was abandoned and the alloy was tested in the poly-crystalline form.

Ferromagnetic Alloys In The System Cu-Mn-Zn, W. Michael Yim

Bachelors Theses and Reports, 1928 - 1970

The purpose of this investigation is to determine whether ferromagnetic alloys exist in the ternary sys­tem Cu-Mn-Zn analogous to the other Heusler alloys. The work in this thesis is a preliminary investi­gation on these alloys using a common metallographic re­search technique and augmented with X-ray methods.

Electroplating Of Chromium Upon A Nickel Plated Magnesium Alloy, Harmel Dawson

Bachelors Theses and Reports, 1928 - 1970

A nickel plating operation for magnesium alloys was investigated and proved successful in plating a small sample of a typical commercial magnesium alloy, Dowmetal J1.

Electrolytic Deposition Of Iron, Irving M. Kenoffel

Bachelors Theses and Reports, 1928 - 1970

In this thesis the purpose was to obtain a good iron deposit from a relatively simple bath. The deposit was to be of good nature and low in Carbon content. Also included is a summary of the uses to which electrolytic iron can be put as well as a summary of work done by other researchers in depositing iron electrolytically.

The Effects Of Some Percentages Of Nickel On The Annealing Of Cartridge Brass, A. Edward Zezula

Bachelors Theses and Reports, 1928 - 1970

The most important element in the alloying of steels, has also been used quite extensively as a third constituent in copper-zinc alloys. The chief characteristics of nickel which make it desirable as an alloying element are its toughness, high strength, and resistance to corrosion.

Electrical Resistivity Measurements Of Powder Metal Compacts, John M. Fitzpatrick

Bachelors Theses and Reports, 1928 - 1970

This work, as it was originally planned, was the arranging of an apparatus whereby electrical resistivity measurements could be made on powder compacts. It was also to include measurements on a series of copper-nickel compacts both before and after sintering.

Some Preliminary Investiagtions Of The Magnetic Permeabilities Of Alloys Of The Ferromagnetic Metals, John H. Gambill Jr.

Bachelors Theses and Reports, 1928 - 1970

The problem presented for this thesis was an investigation of the magnetic properties of the alloys produced by the methods of powder metallurgy. The question behind this was the correlation of the magnetic properties with the bonding properties and with the diffusion of the constituents.

Powder Metallurgy, Cecil R. Waldron

Bachelors Theses and Reports, 1928 - 1970

The metal powders may be produced in a number of different ways. In metals where the intercrystalline material is brittle enough, they may be ground in a ball mill or eddy mill. The fineness of such a powder is more or less controlled by the grain size of the original metal.

The Electrical Conductivity Of The Copper-Aluminum Alloys., William W. Hintalla

Bachelors Theses and Reports, 1928 - 1970

Among the many aluminum alloys which have been studied are the binary copper-aluminum alloys. These have proven to be among the most useful of the alumi­num alloys thus far worked upon.

The Electrolytic Deposition Of Chromium Upon Aluminum, E. Fults, L. D. Voerge

Bachelors Theses and Reports, 1928 - 1970

The purpose or this investigation is primarily to determine the best conditions for plating chromium on aluminum. The work was carried out with the hope of obtaining coherent deposits, and of determin­ing the conditions under which such deposits may be duplicated.