Stephen D. Nunn

Gelcasting : From laboratory development toward industrial production

Gelcasting, a ceramic forming process, was developed to overcome some of the limitations of other complex-shape forming techniques such as injection molding and slip casting. In gelcasting, a concentrated slurry of ceramic powder in a solution of organic monomers is poured into a mold and then polymerized in situ to form a green body in the shape of the mold cavity. Thus, it is a combination of polymer chemistry with slip processing and represents minimal departure from standard ceramic processing. The simplicity of the process has attracted industrial partners and by collaboration between them and the developers, the process is being advanced from the laboratory toward industrial production.

Gelcast Tooling: Net Shape Casting and Green Machining

Abstract Gelcasting is an advanced powder forming process. It is most commonly used to form ceramic or metal powders into complex, near-net shapes. Turbine rotors, gears, nozzles, and crucibles have been successfully gelcast in silicon nitride, alumina, nickel-based superalloy, and several steels. Gelcasting can also be used to make blanks that can be green machined to near-net shape and then high fired. Green machining has been successfully applied to both ceramic and metal gelcast blanks. Recently, we have used gelcasting to make toolinj; for metal casting applications. Most of the work has centered on H13 tool steel. We have demonstrated an ability to gelcast and sinter H13 to near net shape for metal casting tooling. We have also been successful in green machining gelcast blanks using a three-axis CNC milling machine.

Consolidation Process in Near Net Shape Manufacturing of Armstrong CP-Ti/Ti-6Al-4V Powders

This paper summarizes our recent efforts to develop the manufacturing technologies of consolidated net-shape components by using new low-cost commercially pure titanium (CP-Ti) and Ti-6Al-4V alloy powders made by the Armstrong process. Fabrication processes of net shape/ near net shape components, such as uniaxial die-pressing, cold isostatic pressing (CIP), sintering, roll compaction and stamping, have been evaluated. The press-and-sinter processing of the powders were systematically investigated in terms of theoretical density and microstructure as a function of time, pressure, and temperature. Up to 96.4% theoretical density has been achieved with the press-and-sinter technology. Tensile properties of the consolidated samples exhibit good ductility as well as equivalent yield/ultimate tensile strengths to those of fully consolidate materials, even with the presence of a certain amount of porosity. A consolidation model is also under development to interpret the powder deformation during processing. Net shape components made of the Armstrong powder can successfully be fabricated with clearer surface details by using press-and-sinter processing.

Current Status of Ti PM: Progress, Opportunities and Challenges

Utilization of titanium components made by powder metallurgy methods has had limited acceptance largely due to the high cost of titanium (Ti) powder. There has been renewed interest in lower cost economical powders and several Ti reduction methods that produce a particulate product show promise. This talk summarizes work done at Oak Ridge National Laboratory to consolidate these economical powders into mill products. Press and sinter consolidation, hot isostatic pressing (HIP) and direct roll consolidation to make sheet have been explored. The characteristics of the consolidated products will be described as a function of the consolidation parameters.

Silicon nitride containing rare earth silicate intergranular phases

Si[sub 3]N[sub 4] ceramics prepared with refractory grain boundary phases to improve high temperature properties are difficult to density by conventional sintering methods. Gas-pressure sintering may be used to promote densification and development of acicular grains for improved fracture toughness. The current study examined rare earth silicate sintering aids with the composition M[sub 2]Si[sub 2]O[sub 7], where M is a trivalent cation (Y, La, Nd). M[sub 2]O[sub 3] and SiO[sub 2] additions were varied to develop a number of compositions in the Si[sub 3]N[sub 4]-Si[sub 2]N[sub 2]O-M[sub 2]Si[sub 2]O[sub 7] ternary phase field. Pressureless sintering and gas-pressure sintering were used to density the samples. Densification, microstructure development, oxidation resistance, and mechanical properties were evaluated and compared with respect to compositional variations and processing conditions.

Powder Metallurgy Fabrication of Molybdenum Accelerator Target Disks

Powder metallurgy approaches for the fabrication of accelerator target disks are being examined to support the development of Mo-99 production by NorthStar Medical Technologies, LLC. An advantage of powder metallurgy is that very little material is wasted and, at present, dense, quality parts are routinely produced from molybdenum powder. The proposed targets, however, are thin wafers, 29 mm in diameter with a thickness of 0.5 mm, with very stringent dimensional tolerances. Although tooling can be machined to very high tolerance levels, the operations of powder feed, pressing and sintering involve complicated mechanisms, each of which affects green density and shrinkage, and therefore the dimensions and shape of the final product. Combinations of powder morphology, lubricants and pressing technique have been explored to produce target disks with minimal variations in thickness and little or no distortion. In addition, sintering conditions that produce densities for optimum target dissolvability are being determined.

Effect of Powder Characteristics on Gas-Pressure Sintering of Si 3 N 4 With Rare Earth Additives

Several Si3N4 powders, synthesized by various methods and having different surface areas, oxygen contents and impurity levels, were examined. During early stage densification, all powders showed similar shrinkage with the diimide derived powder exhibiting delayed α/β transformation compared to the other powders. The diimide and gas-phase derived powders achieved the highest final densities. Improved densification was observed by increasing the oxygen content and this also resulted in high toughness for some materials with rare earth apatite additives. However, the increased oxygen resulted in reduced high temperature strength. Fracture toughnesses (KIc) up to 10 MPa✓m were obtained for some compositions.