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PROJECTS OF INTEREST
HYDROELECTRIC US ARMY CORPS USACERL REPORT ON HVOF
Advanced Industrial Materials (AIM) Program
Office of Industrial Technologies
Energy Efficiency and Renewable Energy
U.S. Department of Energy (DOE)
Advanced Industrial
Materials
(AIM)
Program
Compilation of Project
Summaries and Significant
Accomplishments
FY 1997
Date Published: May 1998
PROJECT SUMMARY
Advanced Industrial Materials (AIM) Program
PROJECT TITLE: Ni3AI and FeAI Technology Transfer
PHASE: FY 1997 PHASE COMPLETION DATE:
PERFORMING ORGANIZATION(S): Oak
Ridge National Laboratory (ORNL)
PRINCIPAL INVESTIGATOR(S): V. K. Sikka, (423-574-5112); G.
Aramayo, (423-574-6503) M. L. Santella, (423-574-4805);
and R. W. Swindeman, (423-574-5108)
PHASE OBJECTIVE: To promote the technology transfer of
Ni3AI-based nickel aluminide and FeAI-based iron aluminide alloys
in the broadest spectrum of industry possible.
ULTIMATE OBJECTIVE: The ultimate objective is to take
advantage of excellent oxidation and carburization resistance's
and higher strength of nickel and iron aluminides for a broad
range of manufacturing-related industry applications. The
applications identified to date include: furnace furniture
(trays, fixtures, transfer rolls, belts, and conveyors),
hot-pressing or forging dies, cast heating elements, and burners
for gas fired furnaces.
TECHNICAL APPROACH: Since castings are the most likely
near-term applications for both nickel and iron aluminides, the
technical approach has been to address issues related to
castings. These include: (1) optimization of a high-strength
castable composition; (2) castability (mold type, fluidity,
hot-shortness, porosity, and solidification modeling); (3) weld
repairability of castings, welding for component fabrication and
weldment properties; and (4) workability of cast or powder
metallurgy product to sheet, bar, and wire.
PROGRESS: Production, welding, and application-related
issues were addressed. New compositions were identified to be
free of the eutectic formation at 1174C and high- temperature
(1150 to 1200C) mechanical property data were developed for the
new compositions (IC-396LZr and IC-438). A composition (B13) was
identified for its excellent corrosion resistance in various
aqueous solutions and for its high room- temperature hardness. A
weld wire composition was identified and produced in pilot
quantities for producing crack-free root passes in component
welds.
PROJECT SUMMARY (Continued)
Advanced Industrial
Materials (AIM) Program
PROJECT TITLE: Ni3Al and FeAI Technology Transfer
Patents: 2 Publications: 5 Proceedings: 4
Books: 1* Presentations: 6 Awards: I
*Co.edited the volume entitled Proceedings
of the International Symposium on Nickel and Iron Aluminides:
Processing, Properties, and Applications, ASM-TMS
Materials Week 96, Cincinnati, Ohio, 1997.
ACCOMPLISHMENTS:
Licenses: Three new licenses were signed. These were for sand and
centrifugal castings with Alloy Engineering & Casting
Company, centrifugal castings with Sandusky International, and
weld wire with Polymet Corporation.
Other Successful Technology Transfer Activities as Evidence of
Industry Interest:
1.) Testing was continued on a number of fixtures and trays by
Delphi Saginaw in their production batch and pusher carburizing
furnaces; 2.) Rolls at Bethlehem Steel Corporation (two of the
rolls have completed three and one-half years of successful
testing); 3.) A full furnace replacement order for trays from The
Timken Company for their carburizing furnace and a full furnace
order of tube hangers from Chevron.
CRITICAL ISSUES: Although significant progress was made during FY
1997, welding of nickel aluminides still continues to be a
critical issue. Hot fabrication of aluminides is the second
critical issue.
FUTURE PLANS: Continue Ni3AI- and FeAl-base alloy technology
transfer through solving technical issues, prototype
manufacturing, and in-plant testing.
POTENTIAL PAYOFF: Nickel and iron aluminide components for a
range of applications with major benefits of U.S. industry are
gaining a competitive position in the world. Industries
benefiting from nickel aluminide technology include steel,
chemical, heat treating, forging, and the manufacturing sector.
SIGNIFICANT ACCOMPLISHMENT
Advanced Industrial Materials (AIM) Program
High-Velocity Oxy Fuel (HYOF) Spraying of Nickel Aluminide on
Cast Stainless
Steel Rolls Paves the Way for New Applications
ISSUE: Nickel aluminides offer excellent resistance to
high-temperature oxidation and carburizing. and, in most cases,
it is being used as cast components. However, there are
situations where it is desirable to only modify the surface of
the components with nickel aluminide. The high-velocity oxy fuel
(HVOF) process enables the successful application of fully dense
coatings of nickel aluminide onto cast stainless steel pipe.
RESULTS: Nickel aluminide alloy IC-5O powder, produced by Ametek
Specialty Metal Products I)ivision (Eighty-Four, Pennsylvania),
was HVOF sprayed by National Thermospray, Inc. (Cypress, Texas)
onto aluminum, carbon steel, and stainless steel test blocks.
Following coupon testing, a full-size super 22H roll was coated
to a thickness of 0. 125 in. with IC-5O followed by its grinding
to 0.110 in. Photographs of the rolls being sprayed and after
grinding are shown below. The HVOF-coated roll has been in
service in a stainless steel annealing furnace over the past six
months.
ENERGY EFFICIENCY: Both extended
roll life and reduced furnace down time contribute significantly
to energy savings in the stainless steel annealing process.
Research performed at the Oak Ridge National Laboratory,
sponsored by the U.S. Department of
Energy. Assistant Secretary for Energy Efficiency and Renewable
Energy. Office of Industrial
Technologies. Advanced Industrial Materials Program, and the
Steel Industry Team under
contract DE-ACO5-960R22464 with Lockheed Martin Energy Research
Corporation.
NATIONAL THERMOSPRAY, INC.
5120 Oak Ave.
Pasadena, Texas 77503
Contact Ken Norris
OFFICE: 281-373-0609 or 281-991-1133
Cell 713-898-6844
FAX: 281-991-9911