James Gordon Hemrick

Thermal Conductivity of Alumina Measured with Three Techniques

Three common ASTM methods (calorimetry, hot-wire, and laser-flash) for determining the thermal conductivity of refractory ceramics were compared using a commonly available bulk material having a microstructure sufficient for all three methods of analysis. Experimental measurements were made between 20–1200°C on a fine-grained, 94 % pure aluminum oxide using each technique. Results from the hot-wire and laser-flash methods were found to be similar and in line with theoretical and literature values. Values obtained by the calorimetry method were found to be lower than those of the other two methods, with a greater deviation at lower temperatures than at higher temperatures.

Release behavior for powder injection molding in stereolithography molds

Adhesion has been measured between a powder injection molded (PIM) part and the stereolithography epoxy mold surrounding it after cooling. Analysis of release behavior suggests a link to the thermal properties of the mold material. Subsequent measurements of cooling in the part and at the part/mold interface are consistent with a one‐dimensional heat transfer model. Adhesion development at the part/mold interface shows a complex dependence on the thermal characteristics of both the mold and the PIM feedstock.

Improved Furnace Efficiency through the Use of Refractory Materials

This paper describes efforts performed at Oak Ridge National Laboratory (ORNL), in collaboration with industrial refractory manufacturers, refractory users, and academic institutions, to improve energy efficiency of U.S. industry through increased furnace efficiency brought about by the employment of novel refractory systems and techniques. Work in furnace applications related to aluminum, gasification, and lime are discussed. The energy savings strategies discussed are achieved through reduction of chemical reactions, elimination of mechanical degradation caused by the service environment, reduction of temperature limitations of materials, and elimination of costly installation and repair needs. Key results of several case studies resulting from a US Department of Energy (DOE) funded research program are discussed with emphasis on applicability of these results to high temperature furnace applications.

Additional Characterization of Min-K TE-1400 Thermal Insulation

Min-K 1400TE (Thermal Ceramics, Augusta, Georgia) insulation material was further characterized at Oak Ridge National Laboratory (ORNL) for use in structural applications under gradient temperature conditions in an inert environment. Original characterization of Min-K was undertaken from April 1997 to July 2008 to determine its high temperature compressive strength and stress relaxation behavior up to 900 C in helium along with the formulation of a general model for the mechanical behavior exhibited by Min-K under these conditions. The additional testing described in this report was undertaken from April 2009 to June 2010 in an effort to further evaluate the mechanical behavior of Min-K when subjected to a variety of conditions including alternative test temperatures and time scales than previously measured. The behavior of Min-K under changing environments (temperature and strain), lateral loads, and additional isothermal temperatures was therefore explored.

Nano-Scale Interpenetrating Phase Composites (IPC S) for Industrial and Vehicle Applications

A one-year project was completed at Oak Ridge National Laboratory (ORNL) to explore the technical and economic feasibility of producing nano-scale Interpenetrating Phase Composite (IPC) components of a usable size for actual testing/implementation in a real applications such as high wear/corrosion resistant refractory shapes for industrial applications, lightweight vehicle braking system components, or lower cost/higher performance military body and vehicle armor. Nano-scale IPC s with improved mechanical, electrical, and thermal properties have previously been demonstrated at the lab scale, but have been limited in size. The work performed under this project was focused on investigating the ability to take the current traditional lab scale processes to a manufacturing scale through scaling of these processes or through the utilization of an alternative high-temperature process.

Characterization of Min-K TE-1400 Thermal Insulation (Two-Year Gradient Stress Relaxation Testing Update)

Min-K 1400TE insulation material was characterized at Oak Ridge National Laboratory for use in structural applications under gradient temperature conditions. A previous report (ORNL/TM-2008/089) discusses the testing and results from the original three year duration of the project. This testing included compression testing to determine the effect of sample size and test specimen geometry on the compressive strength of Min-K, subsequent compression testing on cylindrical specimens to determine loading rates for stress relaxation testing, isothermal stress relaxation testing, and gradient stress relaxation testing. This report presents the results from the continuation of the gradient temperature stress relaxation testing and the resulting updated modeling.