Publications

The System of Labs Direct Fabrication Technology program was intended to foster cooperation and development in a cooperative effort between Sandia National Labs, Idaho National Energy and Environment Lab and Oak Ridge National Lab. The goal of this program was to bring together LENS (Laser Engineered Net Shaping) from Sandia, INEEL's spray forming process and the alloy development expertise of ORNL. This program investigated the feasibility of combining the LENS and spray forming processes to exploit the best features of both approaches. Further, since both processes were thought to result in a rapidly solidified structure, the alloy design expertise of ORNL offered the opportunity for alloy design or processing options which could more fully utilize the unique capabilities of the processes.

Rapid Prototyping and Near Net Shape manufacturing technologies are the subject of considerable attention and development efforts. At Sandia National Laboratories, one such effort is LENS (Laser Engineered Net Shaping). The LENS process utilizes a stream of powder and a focused Nd YAG laser to build near net shape fully dense metal parts. In this process, a 3-D solid model is sliced, then an X-Y table is rastered under the beam to build each slice. The laser 1 powder head is incremented upward with each slice and the deposition process is controlled via shuttering of the laser. At present, this process is capable of producing fully dense metal parts of iron, nickel and titanium alloys including tool steels and aluminides. Tungsten components have also been produced. A unique aspect of this process is the ability to produce components wherein the composition varies at differing locations in the part. Such compositional variations may be accomplished in either a stepped or graded fashion. In this paper, the details of the process will be described. The deposition mechanism will be characterized and microstructures and their associated properties will be discussed. Examples of parts which have been produced will be shown and issues regarding dimensional control and surface finish will be addressed.

Typical industrial ESR melting practice includes operation at a constant current. This constant current operation is achieved through the use of a power supply whose output provides this constant current characteristic. Analysis of this melting mode indicates that the ESR process under conditions of constant current is inherently unstable. Analysis also indicates that ESR melting under the condition of a constant applied voltage yields a process which is inherently stable. This paper reviews the process stability arguments for both constant current and constant voltage operation. Explanations are given as to why there is a difference between the two modes of operation. Finally, constant voltage process considerations such as melt rate control, response to electrode anomalies and impact on solidification will be discussed.

Within the DOE complex there exists a tremendous quantity of radioactive scrap metal. As an example, it is estimated that within the gaseous diffusion plants there exists in excess of 700,000 tons of contaminated stainless steel. At present, valuable material is being disposed of when it could be converted into a high quality product. Liquid metal processing represents a true recycling opportunity for this material. By applying the primary production processes towards the material`s decontamination and re-use, the value of the strategic resource is maintained while drastically reducing the volume of material in need of burial. Potential processes for the liquid metal decontamination of radioactively contaminated metal are discussed and contrasted. Opportunities and technology development issues are identified and discussed. The processes compared are: surface decontamination; size reduction, packaging and burial; melting technologies; electric arc melting; plasma arc centrifugal treatment; air induction melting; vacuum induction melting; and vacuum induction melting and electroslag remelting.

Analysis of processes used for the production of single crystal turbine components reveals significant shortcomings. Inadequate consideration has been made of the fact the system is cooling dominated and that the amount of cooling tends to increase as the emissive cooling area expands during the process. Experimental evidence suggests that during processing, this increased cooling causes the solidification interface to move away from the baffle and become curved. The motion of the interface results in a decrease in the solidification gradient. The combination of these actions can result in variations in PDAS (primary dendrite arm spacing), grain misalignment and the production of defects. It is shown that despite this tendency, microstructural stabilization may be achieved through the use of the heat of fusion as an internal process heat source.