New Nuclear Reactors for Cleaner, Lower Cost Energy

This topic brings me a long way back to the beginning of my career. At that time I was employed by Sylvania-Corning in their Research Laboratory in Bayside, New York  to develop new materials for a nuclear reactor that would permit a plane to fly continuously without ever landing. General Electric was the prime contractor. Unfortunately the reactor was so heavy compared with the lift capacity of the plane, therefore an impractical application.
However, there were many things that we developed that were incorporated into a novice nuclear program that led to the application of today's nuclear reactors for electrical energy and to the nuclear reactors that serve to power our modern submarines and aircraft carriers.
However, now forty years have passed and these reactors are being extended beyond their intended time limit of service. Efforts are still being made to extend their life for an additional twenty years.
These reactors are large and the efficiency level is decreasing as life is extended. In addition, America has remained stagnant in development and modernization of existing reactors, compared with European countries.
It is refreshing to know that the Department of Energy is now very active in programs to decrease the size of future reactors while improving efficiency at lower cost. In addition, a new factor has entered the equation. In the past we did not consider acts of terrorism to be a big issue. Now these are issues to be seriously considered and become part of the technology in developing new reactors for tomorrow.
To permit development of these  lighter efficient reactors, new concepts have been developed that require improved efficiency in cooling to permit the reactors to operate at higher temperature and pressure. Present materials will not have this capability. Therefore there is current interest in the development of new materials that can withstand the higher temperature and pressure that is anticipated. For the new concepts to be exercised these new materials and coolants and reaction to creep and corrosion become immediate areas of influence for success of the concepts. MagnaTech believes that we have some technology to offer in improvement of current and new materials and intend to actively pursue opportunities in the development of these materials. Therefore MagnaTech is interested in partnering with companies that have thermal capability to permit heat treating and reaction of materials that we believe that can improve performance of these potential reactors of tomorrow. Should you believe that you can team with MagnaTech to develop these new materials, we would be pleased to consider a partnership or consulting to develop new materials for these nuclear reactors of the future. Please contact us regarding potential commercial application.

Is There A Need For New Steels?

Hi: Price of gas down to much lower levels. However, that appears to be a sham because now that this price of gas is much more favorable, the States want to increase the cost again through taxation. Obviously there is a continual need for maintenance on the roads,  especially bridges. However, life for these things is at least 30 years and funds were established long ago, by those with vision, to maintain the assets that were constructed. Why then now are we running out of these funds and why a need for a tax increase to pay for what we have already planned for? Well that is politics, and we do not participate in that game.
However, we do have an interest in materials and materials include steel. In fact, when life was more sane, steel was the name of the game. If you wanted to get lofty and fly, then a much more expensive aluminum came into play, because of its low density.
I haven't counted the number of the steels that we have in inventory now, but I would guess a number somewhere in the thousands, including all modifications. Therefore, the question, why is the automotive industry in need of new steels? Well, these days , we can't leave politics out. In addition although fuel, called gas, was great because it provided additional freedom to go farther and see places and things that we only read about. Now, too much of a good things brings problems such as exhaust problems causing bad things such as smog and other related issues.
Well, what is the problem? Aha, it is the steels. They are much too heavy, causing us to use too much gas. Gas isn't bad; steels are.Therefore, let us get rid of those nasty steels that we have used all these years. After all, we have the greatest innovators that were ever born, and in addition we have computers that can remember all this. After all, why should we need to think about this.
Ah, but there is a solution at hand. My gosh, we have been using aluminum all these years to build gadgets that fly and we have been very innovative here. Why not get rid of those nasty steels and use aluminum. Cost, no problem. We will save the cost by saving on gasoline usage. Wow, two problems fixed. 
But how about safety/ After all steels are much stronger and therefore when road rage catches up to us and we get in an accident what bad is going to happen? Not to worry, our modern day engineers can resolve this with the aid of their trusty computer. Problem resolved.
However, we now return to the land of reality. We have a billion dollar industry in existence that has resolved our materials problems for years. Stainless steels evolved from a need to combat corrosion, Tool steels were developed to permit us to machine more and more materials, including steels,  that were harder, more complex and required closer tolerances. In fact there is a family of steels that are called superallys and these, at least in this country, evolved from the evolution of stainless steels.
Well, the steel industry is once again challenged to come up with a new family of steels that can resolve the issue of high cost gasoline plus tax, How can the industry accomplish this need? Well, current thinking is to improve the modulus of elasticity and if possible, decrease the density.  MagnaTech has some ideas regarding this area of opportunity, to resolve some of the current problems. We are currently creating a proposal to accomplish some of these objectives and are interested in partners to share the solution to this current problem. If you are interested, please contact us. We are innovators not producers, and therefore, there could be good profit for you as a manufacturer of what we can innovate. Call or email us at your convenience.Thank you.

A New Concept

Almost six months ago MagnaTech attended a meeting with a diverse group of small businesses that intend to combine with a prime contractor selling  to the government to explore how local small companies could be efficiently utilized to assist the prime in resolution of its problems. The concept was to use the association of the small local companies and their individual talents to combine with the Prime to resolve its specific problems.
At the first meeting ninety small companies were in attendance, and the concept was introduced. Several different categories where the prime was having difficulty  were explored. Ideas of strengths and resolutions were presented. Each  group presented what they considered the strength of the group. We were within a group named maintenance. As part of this group there was a company that specialized in making an instrument that diagnosed problems that occurred within the equipment supplied by the prime. Therefore we focused on the strengths of that company in a supportive roll.
As time progressed and the monthly meetings scheduled occurred, there was a continual reduction in the number of companies present at the start of each succeeding meeting. This decrease resulted because the companies did not see a fit into the final process and objective. The reasons were that as the program jelled, there were less reasons for participation.
Currently the remaining participating companies has reduced to twenty. For the last two sessions, the remaining companies have concentrated on assimulating the ideas presented into an outline that is useful to prepare to compose a White Paper that briefly presents the concept and funding required to prove whether the concept is worthy. A problem requiring solution has been identified by the prime. Now the objective is to assimulate the associated skills of the collective group to propose a resolution of the problem. The group has five pages to convince the government that the concept is valid. If accepted, then the collective would continue to write a proposal, twenty to twenty-five pages in length describing in detail how the group will act collectively to resolve the problem.
MagnaTech is interested in this and similar programs that are coming on stream as a new way of co-operation with primes to accomplish resolution of the prime's problems through the participation of small business and acceptance of ideas for a specific solution. The concept is not new, and the thrust is to provide a collective set of skills rather than a single source for resolution. This is currently a work in progress and it will be interesting in preparation and review of the White Paper. MagnaTech expects to be a strong participant in both cases. 

 

Get Out Your Grills

Just attended a webinar today and never realized that simple things like grills have a corrosion problem. Seems like that investment you made to entertain your friends on a hot summer or beautiful spring day, as you like it, is subject to being an ugly sight in just a couple of years, depending on your environment. When you stop to think about it, most of us toil at the unit, dutifully cooking our favorite specialties in food until the entire crowd is thoroughly sated and then we are too tired to clean up the mess. After all, tomorrow is another day and we will really have energy to do what we needed to do now, before we could procrastinate. In reality, in a couple of years after purchase, when we just had that brilliant idea that we should invite all our friends over again, oops! We are into a problem because the sight that we see as we are ready to cook is ugly. The inside consists of black oxide or carbide scale, if we are lucky. In worst case we can see daylight through holes that have perforated the shell. Certainly the grill and the supports are nothing to write home to mother about either.

What on earth has happened? How could this top of the line piece of equipment be in such a useless state? The problem is that most of us do not understand the damaging effect of heat and  the environment experienced by the grill. After all, we have only used it for a couple of hours and then maybe cleaned and stored it for another day. Unfortunately, over that small period of time, the grill, while at maximum usage, could have reached temperatures as high as 500 degrees centigrade. In addition there was charcoal contained therein and the atmosphere reacting to create either or carburization or oxidation. To accelerate these reactions the normal liquid products being emitted from whatever is being grilled are also dripping and wetting these hot surfaces. Should we further leave the cooling unit outside in the weather, as a thunderstorm quickly arises, more trouble. If we are at the ocean, well, even more trouble because a salt atmosphere enters the equation as well. 

Therefore not only to resolve this kind of problem but all other corrosion problems, billions of dollars are spent yearly for restoration or replacement. In other words, corrosion remains one of the most troublesome problems within the world. Replacement or restoration is therefore an expensive proposition. There is therefore a need for improved thin coatings to protect equipment sustaining increasing temperatures in harsh environments to at least extend the useful life cycle. Currently paints, plated surfaces, polymers and ceramics are used to accomplish these objectives. 

Plated surfaces are  creating problems because plated surfaces contain metals that are now considered to be harmful to health. Therefore those nice chrome plated surfaces are no longer available. Polymers are limited to lower opperating temperatures and ceramics are brittle and tend to chip. 

Therefore there  is a continual search for new coatings to protect surfaces from heat and the environment in which the unit exists. Magnatech participates in this world. We currently have five patents protecting proprietary assets using nanotechnology to create  tough, wear and corrosion resistant surfaces. We also continue to do research in this area that will either improve or restore the surfaces of parts that are subjected to these harsh environments. Perhaps your next grill will have longer life as a result of use of a MagnaTech development. In closing, MagnaTech wishes you a super spring, summer and fall entertaining your friends, hopefully with a surface that will survive all of your basic sins in creating the worst environment for their preservation. Fair Winds!

Aerospace 2016

Well, Christmas over and it is on to a new year. However, some things of the past are reluctant to leave us. In this case Aerospace is a good example. Way back, over 30 years ago, I was directed to develop the first powder metallurgy superalloys that had less than 100 ppm oxygen surface contamination. We were sucessful in introducing a powder form of Udimet 700 and B1900 that satisfied this criteria. As far as I know, these compositions are still the alloys of choice for turbine wheels. What this says is that it has been a long time since there has been meaningful improvement for alloys designated for aerospace applications. Yet the wish is to fly higher and faster in both commercial and space requirements. The current nickel and cobalt base superalloys will not permit this because of  surface deterioration or microstructural change, deteriorating required properties. In addition, surface deterioration due to erosion and corrosion is one of the most expensive problems in the materials world that requires solution. Perhaps 2016 may be the year for at least some advances to be made.
Advanced manufacturing is bringing in completely new concepts to the materials world.  It is only recently that people have started thinking of  creating alloys by melting incremental layers of powder to create shapes not possible before. In the past, there was always the consideration of material removal to create the desired shape. In  turbine components, as much as 85 % of the starting expensive superalloy material was removed to obtain the desired component. Today, using advanced manufacturing, vanes can be created that are not only to shape, but  that can also have internal passages not capable of being created in the past to permit cooling of the aircraft turbine while activated.
This technology is still in initial stages of development. It requires complex three dimensional computer programming and either laser beam or electron beam apparatus to permit melting of powder layers of micrometer thickness, using a highly directional beam of energy to melt these layers incrementally. Using this technology, both inside and outside dimensions can be changed according to the needs of the component being created. This cost of the equipment, $1,000,000,  limits the usage of the process. However, more and more components are being created using the new technology. It is particuarly useful if only one item or a few are required.
In addition to the above, the creation of powders to satisfy the property requirements of the component being created has been limited in chemical composition, and they too are expensive. However, as demand increases so too does the inventory of new powders of desired chemical composition.
Therefore, the beginning of a new year is always an exciting time. People make their wish lists at this time. It certainly will be exciting to see, as the year develops, how much advancement will be made to innovate new equipment and powder to continue to create parts not possible before, and at lower cost with less threat to the environment. Yes, 2016 looks to be a year where major problems may be resolved.

Full of Gas

Since ancient days it has been known that the world consists of solids, liquids and gases. In this issue I would like to limit my comments to the gas phase. In particular I would like to zoom in on the uses of gases in the heat treating world.
 Without solids, the heat treating world would have no need of gases. However, in discussing solids, they too must be broken down further. Solids have what is called a core, or body, and also a surface. A good correlation might be our body, with corresponding skin as the protection for it. In the case of our body or that of a solid, such as a metal, each has different constituents that determine how each will function.
In the case of the body the properties required include the ability to withstand loads under static conditions, and to have sufficient ductility to warn of potential failure in the case of overload. This is the case in design of buildings and similar type structures.
However, these applications are but a small part of the use of metals. When we consider applications that are moving, then we consider what are characterized as dynamic properties. In this case, the body is moving and in doing so, it can require properties that resist impact, torsion, bending, compression, as well as tension, If used at elevated temperatures the additional consideration of stress rupture and creep becomes of importance.
I could continue, but the purpose of this post is to discuss gases important for heat treating.
We have discussed briefly the properties required of a metal structure. The properties of the surface are entirely different. Like the human body, the surface of the metal protects it from damage from the surrounding environment that could affect its performance by weakening the body through undesirable reaction with the constituents of the external environment. A classic example of this is rust on a car, or the green tinge that occurs with time on copper alloyed building fronts or statues. This is what you see with the eye. However, with the lapse of time what you see externally can occur throughout the entire body, resulting in inability of the body to function and do its job. This can happen quickly or over a significant period of time. However, when it does, structural damage is sufficient to cause either the structure to no longer function, often with damage, or termination of life to the people expecting its ability to do its job.
In respect to the body, the constituents of gases may be important to either the creation of the required properties or to its destruction. In steels, in particular, carbon is the major alloying element, providing the required strength to sustain the loading the component is to sustain. Many gases contain carbon, such as carbon monoxide, methane, acetylene, carbon dioxide, ethane and many more. In the case of powder metallurgy parts, these are compacted from powder and, depending on the compacting pressure, porosity exists throughout the part. Depending on the density, pores may be interconnected or segregated. In the case of parts containing interconnected porosity, a gas, such as methane, can enter the body through the interconnected porosity, thereby reacting with the alloying elements present to form carbides or phases that can markedly change the properties of the alloy being heat treated. Nitrogen is another element present in gases that can also infiltrate the porosity, contributing strengthening nitrides, or entering into solid solution to strengthen the alloy. You can therefore understand that in powder metallurgy it may be possible to compact a powder that is without carbon or nitrogen, therefore softer, permitting compaction to higher density, and then use a gaseous compound, such as methane, to nicrease the strength of the steel.
However, a steel, or any other alloy, is not going to maintain these properties from the environment unless a surface is produced that will prevent contamination, such as oxygen, nitrogen or reactive compounds of the elements, to deposit on the surface and diffuse inward with time along grain boundaries to react with alloyed elements or the base metal itself to weaken the alloy, causing subsequent failure. A comparison may be like the clogging of human arteries preventing the flow of blood in the human body. Even argon, an inert gas has been found to react in superalloys where it was used to protect the surface from corrosion to cause pore formation that in time, at high temperature actuates creep, causing stress corrosion.
However, the same carbon or nitrogen components of reactive gases  may be used at the same time to advantage to react with the surface to form hard wear resistant non-reacting carbides or nitrides that prevent corrosive attack  from the environment.These reactions are classified as carburization, nitriding or carbonitriding. There are other protective surfaces that may result from reaction of boron, silicon or oxygen, depending on the alloy composition.
Corrosion is one of the most expensive problems in the materials world today, causing billions of dollars loss of material and sometimes loss of life accordingly. Therefore much of the work that MagnaTech does is directed toward the resolution of problems of reaction of the environment to cause surface deterioration causing corrosion to result. remember that Magnatech does research and does not want to enter into production. We therefore are looking for customers that wish to use our developed technology to produce surfaces, without alteration of required core properties, to resist corrosion, wear, impact and fatigue of alloy parts. As such MagnaTech has five patents that provide economical, environmental friendly protection of surfaces of steels from the environment. In addition MagnaTech has fifty years of experience in the heat treatment and  development of powder metallurgy steels and nonferrous alloys, specializing in the area of stainless steels, superalloys and alloys for magnetic applications. Should you have problems regarding heat treating or production of protective, wear resistant surfaces MagnaTech stands ready to quickly help you to resolve your problems economically in a clean and safe environment. 

Additive Manufacturing

Hi: Time really flies. Have wanted to write a new addition for some time now, but those round to its always seem to pop up. Usually it is because there is a deadline to meet and as usual, ten other things need attention. On the other hand, I always am looking for something new to write about. However, at present, the game in town still appears to  be advanced manufacturing. This technology is not new, being a NASA tool for making objects for space, way back in the 90s. Obviously expense was no problem because they just couldn't find a different way.
Currently, in its wisdom, government has invented a new word called commercialization. What this means is that the government has put out a large outlay of funds for research and now they believe that it is fair to get a return on their investment. Therefore, this expensive technology developed by NASA so many years ago becomes today's commercial reality.There are several factors that make this more practical for consideration. One is the cost of materials. Everyone knows that things cost more today and when they are not readily available, the greater the cost.
Unfortunately most things start out as a solid bar which is forged, extruded or machined, or in some way made into a desired shape, say a gear. To do this, material is removed. If this material is, say a superalloy, the material is expensive, and as much as 80% can be removed as scrap chip. In addition, to make the desired shape, skilled labor is required to satisfy exacting dimensional control to permit the part to function in service and to mate with other parts. I think you can start to understand where I am going in relation to cost.
In addition, there is the matter of time involved. Quite often to just get the material to shape to size can require months. On top of this, in many cases, either one or a few items are required, which in turn adds to cost. Therefore an opening to drive this technology to commercial reality.
This now introduces a complete new industry entitled Advanced Manufacturing. The title covers a myriad of things, but in its most practical sense it requires an exact three dimensional drawing of the object to be made. This can be rapidly produced using a computer and programs developed to create the desired shape. Once the desired object is created, it is then a small matter to make the shape exactly to the size, and very close with little finishing, to the desired dimensions without one chip of scrap being generated. This is accomplished by creating a platform to contain a small layer of powder distributed and raked to a certain height. Once the powder is distributed, normally either a laser or an electron beam traverses the layer of powder, melting the incremental area designated by the three dimensional model. The only powder that is melted is the area that the laser or electron beam traverses. Therefore blind holes can be made, large pockets of undesirable material eliminated, and a desired shape, no matter how complicated be made without creating one machined chip. Once the desired increment of thickness has been formed and melted, another layer of powder is raked over the layer just shaped, again computer driven to form the next small increment of the part, built on top of the layer just created. This process is repeated until the part is built to the exact design of the desired part. Then, with minor finishing the part is ready for service.
The process has now been found to be useful for making parts like prototypes for creating dies for casting, forging and powder metallurgy molding, as well as first-kind products. If the part is not exactly to what is desired, the part is discarded, adjustments made to the three dimensional model, and again a first-kind part is produced in a matter of days, rather than months. Furthermore, a large facility may not be required to make the parts, but a part may become defective and using the technology described either repaired or made in the field, putting the equipment back into service quickly.
Although dormant all these years, this technology is now rapidly being accepted as being an economical process to produce a few parts quickly, in a few days, rather than months. It also is beginning to be understood as a way to quickly repair or create new parts for equipment that is as much as 50 years old and considered as obsolete and parts for replacement unavailable. Technology does move on.