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Cleaning E-Units by Blasting

Description: Abstract: An air-water-abrasive blasting system thoroughly cleans copper parts of E units without damage to the parts. Little abrasive is required because of the continuous recycle of the abrasive slurry.
Date: 1945
Creator: McWherter, Jack R. & Yerazunis, Stephen
Partner: UNT Libraries Government Documents Department

Polishing compound for plastic surfaces

Description: A polishing compound for plastic surfaces is disclosed. The compound contains by weight approximately 4 to 17 parts at least one petroleum distillate lubricant, 1 to 6 parts mineral spirits, 2.5 to 15 parts abrasive particles, and 2.5 to 10 parts water. The abrasive is tripoli or a similar material that contains colloidal silica. Preferably, most of the abrasive particles are less than approximately 10 microns, more preferably less than approximately 5 microns in size. The compound is used on PLEXIGLAS{sup TM}, LEXAN{sup TM}, LUCITE{sup TM}, polyvinyl chloride (PVC) and similar plastic materials whenever a smooth, clear polished surface is desired.
Date: January 1, 1993
Creator: Stowell, M.S.
Partner: UNT Libraries Government Documents Department

The distribution of subsurface damage in fused silica

Description: Managing subsurface damage during the shaping process and removing subsurface damage during the polishing process is essential in the production of low damage density optical components, such as those required for use on high peak power lasers. Removal of subsurface damage, during the polishing process, requires polishing to a depth which is greater than the depth of the residual cracks present following the shaping process. To successfully manage, and ultimately remove subsurface damage, understanding the distribution and character of fractures in the subsurface region introduced during fabrication process is important. We have characterized the depth and morphology of subsurface fractures present following fixed abrasive and loose abrasive grinding processes. At shallow depths lateral cracks and an overlapping series of trailing indentation fractures were found to be present. At greater depths, subsurface damage consists of a series of trailing indentation fractures. The area density of trailing fractures changes as a function of depth, however the length and shape of individual cracks remain nearly constant for a given grinding process. We have developed and applied a model to interpret the depth and crack length distributions of subsurface surface damage in terms of key variables including abrasive size and load.
Date: November 21, 2005
Creator: Miller, P E; Suratwala, T I; Wong, L L; Feit, M D; Menapace, J A; Davis, P J et al.
Partner: UNT Libraries Government Documents Department

Advanced Mud System for Microhole Coiled Tubing Drilling

Description: An advanced mud system was designed and key components were built that augment a coiled tubing drilling (CTD) rig that is designed specifically to drill microholes (less than 4-inch diameter) with advanced drilling techniques. The mud system was tailored to the hydraulics of the hole geometries and rig characteristics required for microholes and is capable of mixing and circulating mud and removing solids while being self contained and having zero discharge capability. Key components of this system are two modified triplex mud pumps (High Pressure Slurry Pumps) for advanced Abrasive Slurry Jetting (ASJ) and a modified Gas-Liquid-Solid (GLS) Separator for well control, flow return and initial processing. The system developed also includes an additional component of an advanced version of ASJ which allows cutting through most all materials encountered in oil and gas wells including steel, cement, and all rock types. It includes new fluids and new ASJ nozzles. The jetting mechanism does not require rotation of the bottom hole assembly or drill string, which is essential for use with Coiled Tubing (CT). It also has low reactive forces acting on the CT and generates cuttings small enough to be easily cleaned from the well bore, which is important in horizontal drilling. These cutting and mud processing components and capabilities compliment the concepts put forth by DOE for microhole coiled tubing drilling (MHTCTD) and should help insure the reality of drilling small diameter holes quickly and inexpensively with a minimal environmental footprint and that is efficient, compact and portable. Other components (site liners, sump and transfer pumps, stacked shakers, filter membranes, etc.. ) of the overall mud system were identified as readily available in industry and will not be purchased until we are ready to drill a specific well.
Date: December 1, 2008
Creator: Oglesby, Kenneth
Partner: UNT Libraries Government Documents Department

Fatigue Testing of Abrasive Water Jet Cut Titanium

Description: Battelle Memorial Institute as part of its U.S. Department of Energy (USDOE) Contract No. DE-AC05-76RL01830 to operate the Pacific Northwest National Laboratory (PNNL) provides technology assistance to qualifying small businesses in association with a Technology Assistance Program (TAP). Qualifying companies are eligible to receive a set quantity of labor associated with specific technical assistance. Having applied for a TAP agreement to assist with fatigue characterization of Abrasive Water Jet (AWJ) cut titanium specimens, the OMAX Corporation was awarded TAP agreement 09-02. This program was specified to cover dynamic testing and analysis of fatigue specimens cut from titanium alloy Ti-6%Al-4%V via AWJ technologies. In association with the TAP agreement, a best effort agreement was made to characterize fatigue specimens based on test conditions supplied by OMAX.
Date: June 8, 2009
Creator: Hovanski, Yuri; Dahl, Michael E. & Williford, Ralph E.
Partner: UNT Libraries Government Documents Department

Working with the superabrasives industry to optimize tooling for grinding brittle materials

Description: The optics manufacturing industry is undertaking a significant modernization, as computer-numeric-controlled (CNC) equipment is joining or replacing open-loop equipment and hand lapping/polishing on the shop floor. Several prototype CNC lens grinding platforms employing ring tools are undergoing development and demonstration at the Center for Optics Manufacturing in Rochester, NY, and several machine tool companies have CNC product lines aimed at the optics industry. Benefits to using CNC ring tool grinding equipment include: essentially unlimited flexibility in selecting radii of curvature without special radiused tooling, the potential for CIM linkages to CAD workstations, and the cultural shift from craftsmen with undocumented procedures to CNC machine operators employing computerized routines for process control. In recent years, these developments, have inspired a number of US optics companies to invest in CNC equipment and participate in process development activities involving bound diamond tooling. This modernization process,extends beyond large optics companies that have historically embraced advanced equipment, to also include smaller optical shops where a shift to CNC equipment requires a significant company commitment. This paper addresses our efforts to optimize fine grinding wheels to support the new generation of CNC equipment. We begin with a discussion of how fine grinding fits into the optical production process, and then describe an initiative for improving the linkage between optics industry and the grinding wheel industry. For the purposes of this paper, we define fine wheels to have diamond sizes below 20 micrometers, which includes wheels used for what is sometimes called medium grinding (e.g. 10-20 micrometers diamond) and for fine grinding (e.g. 2-4 micrometers diamond).
Date: May 1, 1996
Creator: Taylor, J.S.; Piscotty, M.A.; Blaedel, K.L. & Gray, F.A.
Partner: UNT Libraries Government Documents Department

ONLINE MEASUREMENT OF THE PROGRESS OF DECONTAMINATION

Description: In order to determine if the sensor technology and the decontamination technology will face problems once integrated, a feasibility study (see Appendix B) was produced in which the effect of motion on the efficiency of a radiation sensor was measured. It was found that the effect is not negligible; however, it is not catastrophic, and if the sensors are properly calibrated, this obstacle can be overcome. During the first year of this project, many important tasks have been accomplished. The search for radiation sensors provided knowledge on the technologies commercially available. This, in turn, allowed for a proper assessment of the properties, limitations, different methods of measurement, and requirements of a large number of sensors. The best possible characterization and data collection instrument and decontamination technologies were chosen using the requirement information in Appendix A. There are technical problems with installing sensors within the blasting head, such as steel shot and dust interference. Therefore, the sensor array is placed so that it will measure the radioactivity after the blasting. Sensors are rather sensitive, and therefore it is not feasible to place the sensor windows in such an abrasive environment. Other factors, such as the need for radiation hardening in extreme cases, and the possible interference of gamma rays with the radio frequency modem, have been considered. These factors are expected to be negligible and can be revisited at the time of prototype production. Factors that need to be addressed are the vibrations of the blasting unit and how to isolate the sensor array from these. In addition, an electromagnetic survey must be performed to ensure there will be no interference with the electronic component that will be integrated. The integration design is shown in section 4.0.
Date: January 1, 1999
Creator: M.A. Ebadian, Ph.D.
Partner: UNT Libraries Government Documents Department

Decontamination technologies evaluations

Description: Testing has been completed at the Idaho Chemical Processing Plant (ICPP) on in situ recyclable abrasives grit blasting, concrete cleaning (using scabbling, chemicals and electro-kinetics) and laser light ablation of metals. Several small scale tests have also been conducted with strippable coatings, CO{sub 2} pellet blasting and various other techniques. The results of this testing is summarized in this paper.
Date: May 1, 1996
Creator: Tripp, J.
Partner: UNT Libraries Government Documents Department

Surface preparation via grit-blasting for thermal spraying

Description: The major reason for grit blasting for thermal spray applications is to ensure a strong mechanical bond between the substrate and the coating by the enhanced roughening of the substrate material. This study presents five statistically designed experiments that were accomplished to investigate the grit blasting process. The experiments were conducted using a Box statistical design of experiment (SDE) approach. A substantial range of grit blasting parameters and their effect on the resultant substrate roughness were investigated, including grit type, pressure, working distance, and exposure time. The substrates were characterized for surface characteristics using image analysis. These attributes are correlated with the changes in operating parameters. Optimized process parameters for the two machines used in this study as predicted by the SDE analysis are presented.
Date: November 1, 1995
Creator: Varacalle, D.J. Jr.; Lundberg, L.B. & Hartley, R.S.
Partner: UNT Libraries Government Documents Department

Erosion Modeling Analysis For DWPF MFT/SME Tanks

Description: This report presents the application of computational fluid dynamics (CFD) methods to qualitative estimate of the erosion phenomena expected in the actual Slurry Mixer Evaporator (SME) and MFT (Melter Feed Tank) process facilities by calculating erosion drivers. Using the transport equations governing the slurry flow, two erosion mechanisms were considered to evaluate high erosion sites and to investigate the primary cause of erosion damage for the modeling domain representative of the actual mixing process in the SME/MFT vessels. One of the two erosion mechanisms is the abrasive erosion which is worn by high wall shear of viscous liquid or by continuous contact or low-angle collision of the moving solids with rough surface, and the other is the chip-off erosion which is mainly governed by high-angle impingement of particles. Ductile wall material such as stainless steel is damaged by wall mechanism when particles are impinged on the ductile surface of the present coil guide geometry with wide-open space and no closed- and curved-flow path. The previous results show that the primary locations of high erosion due to particle impingement are at the occurrence of sudden change of flow direction, sudden contraction, and flow obstruction.
Date: May 3, 2004
Creator: LEE, SI
Partner: UNT Libraries Government Documents Department

Degradation of structural ceramics by erosion

Description: Materials wastage by solid-particle erosion can be severe and can limit lifetimes. This paper will review the theoretical description of solid-particle erosion in brittle materials, which is well-developed for monolithic ceramics. The models can usually account for effects from the principal projectile properties of size, impact velocity, and impact angle. Materials parameters such as fracture toughness and hardness can be included. Steady-state erosion measurements on a wide variety of ceramics, ranging from Si single crystals to SiC-whisker-reinforced Al{sub 2}O{sub 3}, are reviewed and compared with the models. It is believed that R-curve behavior and/or particle fragmentation is responsible for discrepancies between theory and experimental results for composite ceramics. In addition, the theories make no attempt to describe threshold or incubation effects.
Date: December 1, 1994
Creator: Routbort, J.L.
Partner: UNT Libraries Government Documents Department

Microfabrication of freestanding metal structures released from graphite substrates.

Description: A sacrificial layer is usually used to release electroformed microstructures. Because of the chemistry applied to the sacrificial layer, only a limited number of metals can be used for electroforming. A novel method to fabricate freestanding electroformed copper structures is presented. A graphite substrate allows the release of the metal part, by abrasive removal of the graphite after electroforming. Results on fabrication of high-aspect-ratio freestanding copper grids are presented; these can be used as x-ray collimator in medical imaging to reduce scattered radiation. This process has potential application to the fabrication of injection molds and microparts on pick-and-place carriers for microelectromechanical systems (MEMS).
Date: February 22, 2002
Creator: Makarova, O. V.; Tang, C.-M.; Mancini, D. C.; Moldovan, N.; Divan, R.; Ryding, D. G. et al.
Partner: UNT Libraries Government Documents Department

Metal-Matrix Composites and Thermal Spray Coatings for Earth Moving Machines

Description: In the eighth quarter, investigations in both thrusts focused on abrasive wear characterization. For the steel matrix composites, various systems were tested at DOE Albany Research Center using wear tests which produced low stress scratching, high stress gouging, and gouging and impact wear. Based on the wear results, it is uncertain as to whether the composites created have sufficient wear resistance to provide a 2x life increase in a selectively reinforced component in all applications. High stress component abrasive wear tests were conducted at Caterpillar on arc lamp processed, thermal sprayed components. Testing showed that in many cases, arc lamp processing parameters and resulting fusion were insufficient to prevent coating spallation. Of those coatings which experienced only limited spallation, wear life improvements approached 2x and it is expected that project goals can be met with additional process modifications. An overview of the progress during the 8th quarter of this project is given below. Additional research details are provided in the limited rights appendix to this report.
Date: January 1, 2003
Creator: Weaver, D. Trent; Kiser, Matthew T. & Hawk, Jeffrey
Partner: UNT Libraries Government Documents Department

Metal-Matrix Composites and Thermal Spray Coatings for Earth Moving Machines

Description: In the 10th quarter no further work was conducted on the steel matrix composite element of this project. For this element work is effectively complete and all that remains is the composition of the final report. For the thermal spray coating effort, components coated and fused in the previous quarter were subject to high stress abrasive wear testing. Some complications were encountered with the wear testing, but the tests which were completed successfully showed that the coatings provided wear resistance 5x that of the baseline material. Further wear testing is planned for the 11th and final quarter. An overview of the progress during the 10th quarter of this project is given below. Additional research details are provided in the limited rights appendix to this report.
Date: July 1, 2003
Creator: Weaver, D. Trent & Kiser, Matthew T.
Partner: UNT Libraries Government Documents Department

Mechanisms for fatigue and wear of polysilicon structural thinfilms

Description: Fatigue and wear in micron-scale polysilicon structural films can severely impact the reliability of microelectromechanical systems (MEMS). Despite studies on fatigue and wear behavior of these films, there is still an on-going debate regarding the precise physical mechanisms for these two important failure modes. Although macro-scale silicon does not fatigue, this phenomenon is observed in micron-scale silicon. It is shown that for polysilicon devices fabricated in the MUMPs foundry and SUMMiT process stress-lifetime data exhibits similar trends in ambient air, shorter lifetimes in higher relative humidity environments and no fatigue failure at all in high vacuum. Transmission electron microscopy of the surface oxides of the samples show an approximate four-fold thickening of the oxide at stress concentrations after fatigue failure, but no thickening after fracture in air or after fatigue cycling in vacuo. It is found that such oxide thickening and fatigue failure (in air) occurs in devices with initial oxide thicknesses of {approx}4-20 nm. Such results are interpreted and explained by a reaction layer fatigue mechanism; specifically, moisture-assisted subcritical cracking within a cyclic stress-assisted thickened oxide layer occurs until the crack reaches a critical size to cause catastrophic failure. Polysilicon specimens from the SUMMiT process are used to study wear mechanisms in micron-scale silicon in ambient air. Worn parts are examined by analytical scanning and transmission electron microscopy, while temperature changes are monitored using infrared microscopy. These results are compared with the development of values of static coefficients of friction (COF) with number of wear cycles. Observations show amorphous debris particles ({approx}50-100 nm) created by fracture through the silicon grains ({approx}500 nm), which subsequently oxidize, agglomerate into clusters and create plowing tracks. A nano-crystalline layer ({approx}20-200 nm) forms at worn regions. No dislocations or extreme temperature increases are found, ruling out plasticity and temperature-assisted mechanisms. The COF reaches a ...
Date: December 1, 2006
Creator: Alsem, Daniel Henricus
Partner: UNT Libraries Government Documents Department

ENHANCEMENT OF STRUCTURAL FOAM MATERIALS BY INCORPORATION OF GASIFIER SLAG

Description: As advanced gasification technology is increasingly adopted as an energy source, disposal of the resulting slag will become a problem. We have shown that gasifier slag can be incorporated into foamed glass, which is currently being manufactured as an abrasive and as an insulating material. The slag we add to foamed glass does not simply act as filler, but improves the mechanical properties of the product. Incorporation of gasifier slag can make foamed glass stronger and more abrasion resistant.
Date: March 15, 2006
Creator: Norton, Olin Perry; Palmer, Ronald A. & Ramsey, W. Gene
Partner: UNT Libraries Government Documents Department

HIGH-POWER TURBODRILL AND DRILL BIT FOR DRILLING WITH COILED TUBING

Description: Commercial introduction of Microhole Technology to the gas and oil drilling industry requires an effective downhole drive mechanism which operates efficiently at relatively high RPM and low bit weight for delivering efficient power to the special high RPM drill bit for ensuring both high penetration rate and long bit life. This project entails developing and testing a more efficient 2-7/8 in. diameter Turbodrill and a novel 4-1/8 in. diameter drill bit for drilling with coiled tubing. The high-power Turbodrill were developed to deliver efficient power, and the more durable drill bit employed high-temperature cutters that can more effectively drill hard and abrasive rock. This project teams Schlumberger Smith Neyrfor and Smith Bits, and NASA AMES Research Center with Technology International, Inc (TII), to deliver a downhole, hydraulically-driven power unit, matched with a custom drill bit designed to drill 4-1/8 in. boreholes with a purpose-built coiled tubing rig. The U.S. Department of Energy National Energy Technology Laboratory has funded Technology International Inc. Houston, Texas to develop a higher power Turbodrill and drill bit for use in drilling with a coiled tubing unit. This project entails developing and testing an effective downhole drive mechanism and a novel drill bit for drilling 'microholes' with coiled tubing. The new higher power Turbodrill is shorter, delivers power more efficiently, operates at relatively high revolutions per minute, and requires low weight on bit. The more durable thermally stable diamond drill bit employs high-temperature TSP (thermally stable) diamond cutters that can more effectively drill hard and abrasive rock. Expectations are that widespread adoption of microhole technology could spawn a wave of 'infill development' drilling of wells spaced between existing wells, which could tap potentially billions of barrels of bypassed oil at shallow depths in mature producing areas. At the same time, microhole coiled tube drilling offers the ...
Date: March 31, 2008
Creator: Radtke, Robert; Glowka, David; Rai, Man Mohan; Conroy, David; Beaton, Tim; Seale, Rocky et al.
Partner: UNT Libraries Government Documents Department

Effect of rogue particles on the sub-surface damage of fused silica during grinding/polishing

Description: The distribution and characteristics of surface cracks (i.e., sub-surface damage or scratching) on fused silica formed during grinding/polishing resulting from the addition of rogue particles in the base slurry has been investigated. Fused silica samples (10 cm diameter x 1 cm thick) were: (1) ground by loose abrasive grinding (alumina particles 9-30 {micro}m) on a glass lap with the addition of larger alumina particles at various concentrations with mean sizes ranging from 15-30 {micro}m, or (2) polished (using 0.5 {micro}m cerium oxide slurry) on various laps (polyurethanes pads or pitch) with the addition of larger rogue particles (diamond (4-45 {micro}m), pitch, dust, or dried Ceria slurry agglomerates) at various concentrations. For the resulting ground samples, the crack distributions of the as-prepared surfaces were determined using a polished taper technique. The crack depth was observed to: (1) increase at small concentrations (>10{sup -4} fraction) of rogue particles; and (2) increase with rogue particle concentration to crack depths consistent with that observed when grinding with particles the size of the rogue particles alone. For the polished samples, which were subsequently etched in HF:NH{sub 4}F to expose the surface damage, the resulting scratch properties (type, number density, width, and length) were characterized. The number density of scratches increased exponentially with the size of the rogue diamond at a fixed rogue diamond concentration suggesting that larger particles are more likely to lead to scratching. The length of the scratch was found to increase with rogue particle size, increase with lap viscosity, and decrease with applied load. At high diamond concentrations, the type of scratch transitioned from brittle to ductile and the length of the scratches dramatically increased and extended to the edge of the optic. The observed trends can explained semi-quantitatively in terms of the time needed for a rogue particle to penetrate into ...
Date: May 2, 2007
Creator: Suratwala, T I; Steele, R; Feit, M D; Wong, L; Miller, P E; Menapace, J A et al.
Partner: UNT Libraries Government Documents Department

LTC vacuum blasting maching (concrete): Baseline report: Greenbook (Chapter)

Description: The LTC shot blast technology was tested and is being evaluated at Florida International University (FIU) as a baseline technology. In conjuction with FIU`s evaluation of efficiency and cost, this report covers the evaluation conducted for safety and health issues. It is a commercially available technology and has been used for various projects at locations throughout the country. The LTC 1073 Vacuum Blasting Machine uses a high-capacity, direct-pressure blasting system which incorporates a continuous feed for the blast media. The blast media cleans the surface within the contained brush area of the blast. It incorporates a vacuum system which removes dust and debris from the surface as it is blasted. The safety and health evaluation during the testing demonstration focused on two main areas of exposure: dust and noise. Dust exposure during maintenance activities was minimal, but due to mechanical difficulties dust monitoring could not be conducted during operation. Noise exposure was significant. Further testing for each of these exposures is recommended because of the outdoor environment where the testing demonstration took place. This may cause the results to be inaccurate. It is feasible that the dust and noise levels will be higher in an enclosed environment. In addition, other safety and health issues found were ergonomics, heat stress, tripping hazards, electrical hazards, lockout/tagout, and arm-hand vibration.
Date: July 31, 1997
Partner: UNT Libraries Government Documents Department

Metal-Matrix Composites and Thermal Spray Coatings for Earth Moving Machines

Description: In the ninth quarter, investigations in steel matrix composites focused on characterization of abrasive wear and fracture test coupons in order to gain a better understanding of the material attributes contributing to the observed behavior in each test. Both the wear and fracture work found that the performance of the carbide cermet based composites was significantly affected by the dissolution of the hard particles and the elements added in hopes of discouraging dissolution. both thrusts focused on abrasive wear characterization. In abrasive wear this led to increase matrix hardness which increased wear resistance, however the fracture toughness of the composites were significantly reduced. In contrast, the oxide based composites demonstrated good fracture characteristics and the oxide particles provided superior protection to the high stress gouging wear imparted by pin-abrasion testing. For the thermal spray coating effort, modified coatings and fusing parameters were explored on simulated components. Significant improvements appear to have been achieved, and are demonstrated in the lack of observable cracking in the coatings. The abrasive wear characteristics of these components will be explored in the 10th quarter. An overview of the progress during the 9th quarter of this project is given below. Additional research details are provided in the limited rights appendix to this report.
Date: April 1, 2003
Creator: Weaver, D. Trent; Zok, Frank W.; Levi, Carlos G. & Kiser, Matthew T.
Partner: UNT Libraries Government Documents Department

Deburring: technical capabilities and cost-effective approaches, Lessons 9 and 10

Description: Abrasive jet, water jet, and abrasive flow deburring are not panaceas for the world's deburring problems. They do, however, solve many of the problems where burrs are either difficult to reach or amenable to automation. As seen in this lesson, they can deburr miniature parts as well as large parts. In almost every case; however, one will note that accessibility of the burr is the key to the success of these processes. Volumes have been published on the effects of abrasive jet parameters. The reader is encouraged to pursue some of the citations in the Source of Additional Information for further quantitative information. Similarly, data on abrasive flow deburring is also available. Little data, however, has been published on water jet deburring.
Date: June 1, 1980
Creator: Gillespie, L.K.
Partner: UNT Libraries Government Documents Department

Material properties and fracture mechanics in relation to ceramic machining

Description: Material removal rate, surface finish, and subsurface damage are largely governed by fracture mechanics and plastic deformation, when ceramics are machined using abrasive methods. A great deal of work was published on the fracture mechanics of ceramics in the late 1970s and early 1980s, although this work has never resulted in a comprehensive model of the fixed abrasive grinding process. However, a recently published model describes many of the most important features of the loose abrasive machining process, for example depth of damage, surface roughness, and material removal rate. Many of the relations in the loose abrasive machining model can be readily discerned from fracture mechanics models, in terms of material properties. By understanding the mechanisms of material removal, from a material properties perspective, we can better estimate how one material will machine in relation to another. Although the fracture mechanics models may have been developed for loose abrasive machining, the principles of crack initiation and propagation are equally valuable for fixed abrasive machining. This report provides a brief review of fracture in brittle materials, the stress distribution induced by abrasives, critical indenter loads, the extension of cracks, and the relation of the fracture process to material removal.
Date: December 2, 1993
Creator: Griffith, L. V.
Partner: UNT Libraries Government Documents Department