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The PEACE PIPE: Recycling nuclear weapons into a TRU storage/shipping container

Description: This paper describes results of a contract undertaken by the National Conversion Pilot Project (NCPP) at the Rocky Flats Environmental Technology Site (RFETS) to fabricate stainless steel ``pipe`` containers for use in certification testing at Sandia National Lab, Albuquerque to qualify the container for both storage of transuranic (TRU) waste at RFETS and other DOE sites and shipping of the waste to the Waste Isolation Pilot Project (WIPP). The paper includes a description of the nearly ten-fold increase in the amount of contained plutonium enabled by the product design, the preparation and use of former nuclear weapons facilities to fabricate the components, and the rigorous quality assurance and test procedures that were employed. It also describes how stainless steel nuclear weapons components can be converted into these pipe containers, a true ``swords into plowshare`` success story.
Date: March 1, 1997
Creator: Floyd, D.; Edstrom, C.; Biddle, K.; Orlowski, R.; Geinitz, R.; Keenan, K. et al.
Partner: UNT Libraries Government Documents Department

Criteria determining the selection of slags for the melt decontamination of radioactively contaminated stainless steel by electroslag remelting

Description: Electroslag remelting is an excellent process choice for the melt decontamination of radioactively contaminated metals. ESR furnaces are easily enclosed and do not make use of refractories which could complicate thermochemical interactions between molten metal and slag. A variety of cleaning mechanisms are active during melting; radionuclides may be partitioned to the slag by means of thermochemical reaction, electrochemical reaction, or mechanical entrapment. At the completion of melting, the slag is removed from the furnace in solid form. The electroslag process as a whole is greatly affected by the chemical and physical properties of the slag used. When used as a melt decontamination scheme, the ESR process may be optimized by selection of the slag. In this research, stainless steel bars were coated with non-radioactive surrogate elements in order to simulate surface contamination. These bars were electroslag remelted using slags of various chemistries. The slags investigated were ternary mixtures of calcium fluoride, calcium oxide, and alumina. The final chemistries of the stainless steel ingots were compared with those predicted by the use of a Free Energy Minimization Modeling technique. Modeling also provided insight into the chemical mechanisms by which certain elements are captured by a slag. Slag selection was also shown to have an impact on the electrical efficiency of the process as well as the surface quality of the ingots produced.
Date: March 1, 1997
Creator: Buckentin, J.M.R.; Damkroger, B.K.; Shelmidine, G.J. & Atteridge, D.G.
Partner: UNT Libraries Government Documents Department

Evaluation of materials and surface treatments for the DWPF melter pour spout bellows protective liner

Description: A study was undertaken to evaluate a variety of materials and coatings for the DWPF pour spout bellows liner. The intent was to identify materials that would minimize or eliminate adherence of glass on the bellows liner wall and help minimize possible pluggage during glass pouring operations in DWPF. Glass has been observed adhering to the current bellow`s liner, which is made of 304L stainless steel. Materials were identified which successfully allowed molten glass to hit these surfaces and not adhere. Results of this study suggest that if these materials are used in the pouring system glass could still fall into the canister without appreciable plugging, even if an unstable glass stream is produced. The materials should next be evaluated under the most realistic DWPF conditions possible. Other findings of this study include the following: (1) increasing coupon thickness produced a favorable increase in the glass sticking temperature; (2) highly polished surfaces, with the exception of the oxygen-free copper coupon coated with Armoloy dense chromium, did not produce a significant improvement in the glass sticking temperature, increasing angle of contact of the coupon to the falling glass did not yield a significant performance improvement; (3) electroplating with gold and silver and various diffusion coatings did not produce a significant increase in the glass sticking temperature. However, they may provide added oxidation and corrosion resistance for copper and bronze liners. Boron nitride coatings delaminated immediately after contact with the molten glass.
Date: June 27, 1997
Creator: Imrich, K.J.; Bickford, D.F. & Wicks, G.G.
Partner: UNT Libraries Government Documents Department

Beam-broadening effects in STEM/EDS measurement of radiation-induced segregation in high-purity 304L stainless steel

Description: Radiation-induced segregation (RIS) is the spatial redistribution of elements at defect sinks such as grain boundaries and free surfaces during irradiation. This phenomenon has been studied in a wide variety of alloys and has been linked to irradiation-assisted stress corrosion cracking (IASCC) of nuclear reactor core components. Therefore, accurate determination of the grain boundary composition is important in understanding its effects on environmental cracking. Radiation-induced segregation profiles are routinely measured by scanning-transmission electron microscopy using energy-dispersive X-ray spectroscopy (STEM-EDS) and Auger electron spectroscopy (AES). Because of the narrow width of the segregation profile (typically less than 10-nm full width at half-maximum), the accuracy of grain boundary concentration measurements using STEM/EDS depends on the characteristics of the analyzing instrument, specifically, the excited volume in which x-rays are generated. This excited volume is determined by both electron beam diameter and the primary electron beam energy. Increasing the primary beam energy in STEM/EDS produces greater measured grain boundary segregation, as the reduced electron beam broadening a smaller excited volume. In this work, the effect of beam broadening is assessed on segregation measurements in a 304L stainless steel sample irradiated with 3.2 MeV protons at 400 C to doses of 3.0 and 0.1 dpa. The STEM/EDS measurements are also compared to measurements made using AES.
Date: October 1997
Creator: Busby, J. T.; Was, G. S.; Allen, T. R.; Kenik, E. A. & Zaluzec, N. J.
Partner: UNT Libraries Government Documents Department

Analysis of cracking of co-extruded recovery boiler floor tubes

Description: Cracking of the stainless steel layer in co-extruded 304L/SA210 tubing used in black liquor recovery boilers is being found in an ever-increasing number of North American pulp and paper mills. Because of the possibility of a tube failure, this is a significant safety issue, and, because of the extra time required for tube inspection and repair, this can become an economic issue as well. In a project funded by the U.S. Department of Energy and given wide support among paper companies, boiler manufacturers, and tube fabricators, studies are being conducted to determine the cause of the cracking and to identify alternate materials and/or operating procedures to prevent tube cracking. Examination of cracked tubes has permitted characterization of crack features, and transmission electron microscopy is providing information about the thermal history, particularly cyclic thermal exposures, that tubes have experienced. Neutron and x-ray diffraction techniques are being used to determine the residual stresses in as-fabricated tube panels and exposed tubes, and finite element modeling is providing information about the stresses the tubes experience during operation. Laboratory studies are being conducted to determine the susceptibility of the co-extruded 304L/SA210 tubes to stress corrosion cracking, thermal fatigue, and corrosion in molten smelt. This paper presents the current status of these studies. On the basis of all of these studies, recommendations for means to prevent tube cracking will be offered.
Date: August 1, 1997
Creator: Keiser, J.R.; Taljat, B. & Wang, X.L.
Partner: UNT Libraries Government Documents Department

A multi-level code for metallurgical effects in metal-forming processes

Description: The authors present the final report on a Laboratory-Directed Research and Development (LDRD) project, A Multi-level Code for Metallurgical Effects in metal-Forming Processes, performed during the fiscal years 1995 and 1996. The project focused on the development of new modeling capabilities for simulating forging and extrusion processes that typically display phenomenology occurring on two different length scales. In support of model fitting and code validation, ring compression and extrusion experiments were performed on 304L stainless steel, a material of interest in DOE nuclear weapons applications.
Date: August 1, 1997
Creator: Taylor, P.A.; Silling, S.A.; Hughes, D.A.; Bammann, D.J. & Chiesa, M.L.
Partner: UNT Libraries Government Documents Department

The effects of 800 MeV proton irradiation on the corrosion of tungsten, tantalum, stainless steel, and gold

Description: Real time electrochemical data were acquired for tungsten, tantalum, stainless steel 304L, and gold targets during proton irradiation at the LANSCE Weapons Neutron Research Facility. The goal of this research was to establish a better understanding of the corrosion properties of materials as a function of proton irradiation and gain insight into the mechanism of the observed phenomena. The following electrochemical observations were made during proton irradiation of W, Ta, SS304, and Au: (1) the open circuit potential of all materials increased with increasing proton fluence; (2) the corrosion rate (at the OCP) of W and SS304 increased with increasing proton fluence; (3) the passive dissolution rate for SS304 and Ta decreased with increasing proton fluence; (4) the anodic dissolution rate for W increased with increasing proton fluence; (5) the pitting potential for SS304 increased with proton fluence, which is an indication that the material is less susceptible to pitting attack during irradiation.
Date: December 1, 1997
Creator: Lillard, R.S.; Butt, D.P.; Kanner, G. & Daemen, L.
Partner: UNT Libraries Government Documents Department

Spallation source materials test program

Description: A spallation source materials program has been developed to irradiate and test candidate materials (Inconel 718, 316L and 304L stainless steel, modified 9Cr-1Mo(T91), Al6061-T6, Al5052-O) for use in the Accelerator Production of Tritium (APT) target and blanket in prototypic proton and neutron fluxes at prototypic temperatures. The study uses the 800 MeV, 1mA proton accelerator at the Los Alamos Neutron Science Center (LANSCE) which produces a Gaussian beam with 2 sigma = 3 cm. The experimental set-up contains prototypic modules of the tungsten neutron source and the lead/aluminum blanket with mechanical testing specimens of candidate APT materials placed in specific locations in the irradiation area. These specimens have been irradiated for greater than 3,600 hours with a maximum proton fluence of 4--5 {times} 10{sup 21} p/cm{sup 2} in the center of the proton beam. Specimens will yield some of the first data on the effect of proton irradiation to high dose on the materials` properties from tensile tests, 3 pt. bend tests, fracture toughness tests, pressurized tubes, U-bend stress corrosion cracking specimens, corrosion measurements and microstructural characterization of transmission electron microscopy specimens.
Date: December 1, 1997
Creator: Maloy, S.A. & Sommer, W.F.
Partner: UNT Libraries Government Documents Department

Application of internal state variable plasticity and damage models to welding

Description: An internal state variable constitutive model coupled with a ductile void growth model is applied in two finite element simulations of welding. Shrinkage of a 304 L stainless steel pipe due to multipass gas tungsten arc welds is presented as an example of tracking distortion far from the weld. Weld solidification cracking in Al-6061 disks is presented as an application of the plasticity model coupled with the damage model.
Date: June 1, 1997
Creator: Dike, J.J.; Ortega, A.R.; Bammann, D.J. & Lathrop, J.F.
Partner: UNT Libraries Government Documents Department

Sensors for feedback controls in solid state resistance welding operations

Description: The Savannah River Site (SRS) has a 40-plus year history of producing and processing tritium primarily for use in nuclear weapons. This gas is stored at high pressures in reservoirs that are manufactured and sealed through the use of special resistance welding processes. There is an interest in maintaining the quality and consistency of these welds to avoid leaks in the reservoirs. The reasons for this are the limited supply and high cost of producing tritium, the necessity of assuring nuclear safety and to promote weapon system reliability. Precisely machined 304-L and 316 stainless steel components are the materials used in the fabrication of the reservoir. This presentation will include a survey of sensors for use in resistance welding processes. The results of the application of the analog laser position sensor will be presented along with data indicating how the displacement parameter defines the weld process. Opportunities to close the control loop by taking sensor data into the weld controller will be discussed.
Date: October 1, 1997
Creator: Tarpley, J.
Partner: UNT Libraries Government Documents Department

Finite element analyses of tool stresses in metal cutting processes

Description: In this report, we analytically predict and examine stresses in tool tips used in high speed orthogonal machining operations. Specifically, one analysis was compared to an existing experimental measurement of stresses in a sapphire tool tip cutting 1020 steel at slow speeds. In addition, two analyses were done of a carbide tool tip in a machining process at higher cutting speeds, in order to compare to experimental results produced as part of this study. The metal being cut was simulated using a Sandia developed damage plasticity material model, which allowed the cutting to occur analytically without prespecifying the line of cutting/failure. The latter analyses incorporated temperature effects on the tool tip. Calculated tool forces and peak stresses matched experimental data to within 20%. Stress contours generally agreed between analysis and experiment. This work could be extended to investigate/predict failures in the tool tip, which would be of great interest to machining shops in understanding how to optimize cost/retooling time.
Date: January 1, 1997
Creator: Kistler, B.L.
Partner: UNT Libraries Government Documents Department

FEA stress analysis for SAFKEG 2863B

Description: This report covers the evaluation of the structural design of the two stainless steel containment vessels in CROFT SAFKEG Model Number 2863B, for conformance to the design criteria of the NRC Regulatory Guide 7.6, NRC Regulatory Guide 7.8, and the applicable requirements of the ASME Boiler and Pressure Vessel Code, Section 3, and Section 8. The two containment vessels are designated Cans 2870 and 2871. Each of these containment vessels was analyzed for the loadings specified in chapter 2, Section 2.1.2 of the SARP. Structural assessment of Cans 2870 and 2871 due to loading considerations beyond the evaluation of pressure and temperature are presented. This report is organized as follows: (1) overview of the design of each containment vessel and pressure boundary; (2) brief description of both containment vessels; (3) discussion of normal and accident conditions; (4) analysis assumptions; (5) detailed structural evaluation of each component of each containment vessel; (6) demonstration of compliance to Regulatory Guide 7.6 stress evaluations; (7) demonstration of compliance to Regulatory Guide 7.8 loading combinations; and (8) summary of the calculated stresses, comparison with design allowables, estimates of margins of safety and a summary of results and conclusions.
Date: July 15, 1997
Creator: Puckett, A.
Partner: UNT Libraries Government Documents Department