Abstract: A uranium-1 to 3 wt. % zirconium alloy characterized by high strength, high ductility and stable microstructure is fabricated by an improved thermal mechanical process. A homogenous ingot of the alloy which has been reduced in thickness of at least 50% in the two-step forging operation, rolled into a plate with a 75% reduction and then heated in vacuum at a temperature of about 750.degree. to 850.degree. C. and then quenched in water is subjected to further thermal-mechanical operation steps to increase the compressive yield strength approximately 30%, stabilize the microstructure, and decrease the variations in mechanical properties throughout the plate is provided. These thermal-mechanical steps are achieved by cold rolling the quenched plate to reduce the thickness thereof about 8 to 12%, aging the cold rolled plate at a first temperature of about 325.degree. to 375.degree. C. for five to six hours and then aging the plate at a higher temperature ranging from 480.degree. to 500.degree. C.

Abstract: Ceramic composites exhibiting increased fracture toughness are produced by the simultaneous codeposition of silicon carbide and titanium disilicide by chemical vapor deposition. A mixture of hydrogen, methyltrichlorosilane and titanium tetrachloride is introduced into a furnace containing a substrate such as graphite or silicon carbide. The thermal decomposition of the methyltrichlorosilane provides a silicon carbide matrix phase and the decomposition of the titanium tetrachloride provides a uniformly dispersed second phase of the intermetallic titanium disilicide within the matrix phase. The fracture toughness of the ceramic composite is in the range of about 6.5 to 7.0 MPa.sqroot.m which represents a significant increase over that of silicon carbide.

Abstract: A chemical vapor deposition (CVD) process for preparing fiber-reinforced ceramic composites. A specially designed apparatus provides a steep thermal gradient across the thickness of a fibrous preform. A flow of gaseous ceramic matrix material is directed into the fibrous preform at the cold surface. The deposition of the matrix occurs progressively from the hot surface of the fibrous preform toward the cold surface. Such deposition prevents the surface of the fibrous preform from becoming plugged. As a result thereof, the flow of reactant matrix gases into the uninfiltrated (undeposited) portion of the fibrous preform occurs throughout the deposition process. The progressive and continuous deposition of ceramic matrix within the fibrous preform provides for a significant reduction in process time over known chemical vapor deposition processes.

Abstract: The present invention is directed to a method for machining optical quality inishes and contour accuracies of workpieces of carbon-containing metals such as steel with diamond tooling. The wear rate of the diamond tooling is significantly reduced by saturating the atmosphere at the interface of the workpiece and the diamond tool with a gaseous hydrocarbon during the machining operation. The presence of the gaseous hydrocarbon effectively eliminates the deterioration of the diamond tool by inhibiting or preventing the conversion of the diamond carbon to graphite carbon at the point of contact between the cutting tool and the workpiece.

Abstract: The present invention is directed to a microwave coupler for enhancing the heating or metallurgical treatment of materials within a cold-wall, rapidly heated cavity as provided by a microwave furnace. The coupling material of the present invention is an alpha-rhombohedral-boron-derivative-structure material such as boron carbide or boron silicide which can be appropriately positioned as a susceptor within the furnace to heat other material or be in powder particulate form so that composites and structures of boron carbide such as cutting tools, grinding wheels and the like can be rapidly and efficiently formed within microwave furnaces.

Abstract: Catalyst for the production of methane from carbon and/or coal by means of catalytic gasification. The catalyst compostion containing at least two alkali metal salts. A particulate carbonaceous substrate or carrier is used.

Abstract: An induction furnace for melting and casting highly pure metals and alloys such as uranium and uranium alloys in such a manner as to minimize contamination of the melt by carbon derived from the materials and the environment within the furnace. The subject furnace is constructed of carbon free materials and is housed within a conventional vacuum chamber. The furnace comprises a ceramic oxide crucible for holding the charge of metal or alloy. The heating of the crucible is achieved by a plasma-sprayed tungsten susceptor surrounding the crucible which, in turn, is heated by an RF induction coil separated from the susceptor by a cylinder of inorganic insulation. The furnace of the present invention is capable of being rapidly cycled from ambient temperatures to about 1650.degree. C. for effectively melting uranium and uranium alloys without the attendant carbon contamination problems previously encountered when using carbon-bearing furnace materials.

Abstract: The present invention is directed to the fabrication of ceramic composites which possess improved mechanical properties especially increased fracture toughness. In the formation of these ceramic composites, the single crystal SiC whiskers are mixed with fine ceramic powders of a ceramic material such as Al.sub.2 O.sub.3, mullite, or B.sub.4 C. The mixtures which contain a homogeneous dispersion of the SiC whiskers are hot pressed at pressures in a range of about 28 to 70 MPa and temperatures in the range of about 1600.degree. to 1950.degree. C. with pressing times varying from about 0.75 to 2.5 hours. The resulting ceramic composites show an increase in fracture toughness of up to about 9 MPa.m.sup.1/2 which represents as much as a two-fold increase over that of the matrix material.

Abstract: In one aspect, the invention comprises a method for producing tools and machine components having superhard crystalline-ceramic work surfaces. Broadly, the method comprises two steps: A tool or machine component having a ceramic near-surface region is mounted in ion-implantation apparatus. The region then is implanted with metal ions to form, in the region, a metastable alloy of the ions and said ceramic. The region containing the alloy is characterized by a significant increase in hardness properties, such as microhardness, fracture-toughness, and/or scratch-resistance. The resulting improved article has good thermal stability at temperatures characteristic of typical tool and machine-component uses. The method is relatively simple and reproducible.

Abstract: The present invention is directed to a containment vessel which is particularly useful in melting aluminum. The vessel of the present invention is a multilayered vessel characterized by being electrically conductive, essentially nonwettable by and nonreactive with molten aluminum. The vessel is formed by coating a tantalum substrate of a suitable configuration with a mixture of yttria and particulate metal borides. The yttria in the coating inhibits the wetting of the coating while the boride particulate material provides the electrical conductivity through the vessel. The vessel of the present invention is particularly suitable for use in melting aluminum by ion bombardment.

Abstract: The present invention is a thermometer used for measuring furnace temperaes in the range of about 1800.degree. to 2700.degree. C. The thermometer comprises a broadband multicolor thermal radiation sensor positioned to be in optical alignment with the end of a blackbody sight tube extending into the furnace. A valve-shutter arrangement is positioned between the radiation sensor and the sight tube and a chamber for containing a charge of high pressure gas is positioned between the valve-shutter arrangement and the radiation sensor. A momentary opening of the valve shutter arrangement allows a pulse of the high gas to purge the sight tube of air-borne thermal radiation contaminants which permits the radiation sensor to accurately measure the thermal radiation emanating from the end of the sight tube.

Abstract: The invention is a flow and pressure-sealing valve for use with abrasive solids. The valve embodies special features which provide for long, reliable operating lifetimes in solids-handling service. The valve includes upper and lower transversely slidable gates, contained in separate chambers. The upper gate provides a solids-flow control function, whereas the lower gate provides a pressure-sealing function. The lower gate is supported by means for (a) lifting that gate into sealing engagement with its seat when the gate is in its open and closed positions and (b) lowering the gate out of contact with its seat to permit abrasion-free transit of the gate between its open and closed positions. When closed, the upper gate isolates the lower gate from the solids. Because of this shielding action, the sealing surface of the lower gate is not exposed to solids during transit or when it is being lifted or lowered.

Abstract: The present invention is directed to a hot pressing furnace or kiln which is capable of preheating, hot pressing, and cooling a plurality of articles in a sequential and continuous manner. The hot pressing furnace of the present invention comprises an elongated, horizontally disposed furnace capable of holding a plurality of displaceable pusher plates each supporting a die body loaded with refractory or ceramic material to be hot pressed. Each of these plates and the die body supported thereby is sequentially pushed through the preheating zone, a temperature stabilizing and a hot pressing zone, and a cooling zone so as to provide a continuous hot-pressing operation of a plurality of articles.

Abstract: A flow work exchanger for use in feeding a reactant material to a high-pressure reactor vessel comprises an outer shell, an inner shell concentrically disposed within said outer shell, means for conducting said reactant into the lower end of said lower shell and then to said reactor vessel, and means for conducting a hotter product effluent from said reactor vessel into the upper end of said inner shell and out of the annulus between said inner and outer shells.

Abstract: Improved spherules for making enhanced forms of nuclear-reactor fuels are prepared by internal gelation procedures within a sol-gel operation and are accomplished by first boiling the concentrated HMTA-urea feed solution before engaging in the spherule-forming operation thereby effectively controlling crystallite size in the product spherules.

Abstract: A pistol-shaped charger assembly clamps a cylindrical radiation dosimeter against one edge thereof. A triggerlike lever on the handgrip of the assembly is manually pivoted to actuate a piezoelectric current generator held in the handgrip and thereby charge the dosimeter.

Abstract: Uranium-rich niobium and niobium-zirconium alloys possess a characteristic known as shape memory effect wherein shaped articles of these alloys recover their original shape when heated. The present invention circumvents this memory behavior by forming the alloys into the desired configuration at elevated temperatures with "cold" matched dies and maintaining the shaped articles between the dies until the articles cool to ambient temperature.

Abstract: A gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to provide a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surfaces are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy contiguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

Abstract: The present invention is directed to a system for sensing and correcting the alignment of a mandrel being wound with filamentary material with respect to the filamentary material winding mechanism. A positioned reference pin attached to the mandrel is positioned in a beam of collimated light emanating from a laser so as to bisect the light beam and create a shadow therebetween. A pair of photocells are positioned to receive the bisected light beam with the shadow uniformly located between the photocells when the pin is in a selected position. The mandrel is supported in the selected position for the winding of a filamentary material by a position adjustable roller mechanism which is coupled by a screw drive to a reversible motor. Changes in the pin position such as caused by winding growth are sensed by the photocells to provide the displacement of the roller mechanism in the direction necessary to return the mandrel to the selected position.

Abstract: Microspheres for nuclear waste storage are formed by gelling droplets containing the waste in a gelation fluid, transferring the gelled droplets to a furnace without the washing step previously used, and heating the unwashed gelled droplets in the furnace under temperature or humidity conditions that result in a substantially linear rate of removal of volatile components therefrom.