Annual Technical Progress Report of Radioisotope Power System Materials Production and Technology Program Tasks for October 1, 2004, Through September 30, 2005 Page: 7 of 43
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2.2 IRIDIUM ALLOY BLANK AND FOIL PRODUCTION
The goals for this activity are to produce prime blanks and foil under full configuration control,
maintain production capability and to supply materials needed for clad vent set demonstration and
maintenance activities. During FY 2005 a total of 307 prime blanks were transferred to the CVS
task. A total of 48 kg of iridium powder was qualified and blended to produce the L-batch of
powder. A technician apprentice was hired and trained in cleaning and rolling of iridium
materials. A vacuum-annealing furnace was obtained from another Oak Ridge site and a new hot
zone received for installation in the furnace. A purchase order was issued for a new rolling mill.
2.2.1 Iridium Powder Procurement and Certification
The L-batch of powder with a total weight of 48 kg was blended in July and August 2005. The
powder consisted of 36 kg of powder purchased in August 2004, an additional 9 kg purchased in
FY 2003, and also 3 kg purchased by another program to replace borrowed iridium. A total of
15kg of the powder received in August 2004 was found nonconforming and returned for
replacement. An additional 1.5 kg was found not conforming but was recommended for use as-is.
This powder was accepted for use during FY 2005.
The powder purchased in FY2003 initially showed carbon contents in the range of 54 to 67 ppm
as compared to a specified maximum of 50 ppm. Multiple repeat samples of the powder showed
carbon contents of 20 to 25 ppm. The powder was accepted for use as-is under NCR-IRB&F-
2151in June 2004.
The 15 kg of powder to replace the returned powder was received in September 2004 and
analyzed in October 2004. Only 6 kg of this powder was found to meet the specification when
sampled and analyzed. A total of 9 kg was found to be nonconforming and was accepted for use
as-is under NCR- IRB&F -2152. Iridium powder Johnson Matthey Lot 0019852 jar IA contained
55 pg/g (55 ppm) ruthenium (Ru) as compared to a specified maximum concentration of 50 pg/g.
Iridium powder Johnson Matthey Lot 0019852 jar 1B contained 110 pg/g (110 ppm) sodium (Na)
as compared to a specified maximum concentration of 100 pg/g. Iridium powder Impala Lot
2003/31Al jar 2 contained 78 pg/g (78 ppm) rhodium (Rh) as compared to a specified maximum
concentration of 70 pg/g. Each of the three jars contained about 3 kg of powder.
An additional 3 kg of powder was purchased during FY 2004 using funds from another program.
This powder was in exchange for iridium alloy scrap material provided to that program. The
material was found to contain 62 pg/g of Ru as compared to the specification requirement of 50
pg/g maximum. This powder was accepted for use as-is under NCR IRB&F 2150.
Iridium powder Anglo Lot 0011 jar 2 received in August 2004 was found to contain 137 ppm
rhodium (Rh) as compared to a specified maximum concentration of 70 ppm. The jar containing
about 1.5 kg of powder was accepted for use as-is under NCR IRB&F 2153 in November 2004.
2.2.2 Blank Production
2.2.2.1 Blank Production from G6 Ingot
The G6 ingot was processed to produce blanks in FY 2004. Chemical and metallographic
analyses of samples from the G6 ingot were successfully completed in November 2005.
Nondestructive testing of blanks from G6 ingot was completed. A total of 84 prime blanks from7
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Annual Technical Progress Report of Radioisotope Power System Materials Production and Technology Program Tasks for October 1, 2004, Through September 30, 2005, report, September 30, 2005; Oak Ridge, Tennessee. (https://digital.library.unt.edu/ark:/67531/metadc895975/m1/7/: accessed April 24, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.