Abstract: This is a process for making a very pure and very homogeneous zirconium material for use in lining the interior of zirconium alloy fuel element cladding. The improvement utilizes the forming of consumable feed material from generally virgin sponge material, melting the consumable feed material in a multiple swept beam electron beam furnace with a feed rate generally between 0.1 and less than about 1.0 inch per hour and then vacuum arc melting the EB melted material.

Abstract: This is a process for making a very pure and very homogeneous material for use in lining the interior of zirconium alloy fuel element cladding. The improvement utilizes the forming of a consumable electrode from generally virgin sponge material, melting the consumable electrode in a multiple swept beam electron beam furnace with a feed rate between 1 and 20 inches per hour and then vacuum arc melting the EB melted material.

Abstract: This is a process which provides the first essentially continuous high tin flow soldering method for attaching copper-based fins to non-copper-based tubing. This invention avoids sludge buildup in the reservoir and generally avoids lead carbonate formation when the heat produced having a braze-like joint with eta phase layers exchanger is in service. In addition, a novel structure is adjacent to copper-containing surfaces. The invention utilizes an essentially lead-free, high tin solder cascade onto a preferably cool tube, genrally with a limited time of contact between the liquid solder and the tube, and with a combination air quench and wipe to remove excess solder and solidify the remaining solder. Thus a braze-like joint is achieved having better heat conduction and closer thermal expansion match. This finned heat exchanger tubing is generally useful for liquid to gas-type heat exchangers.

Abstract: This is a material for lining reactor fuel element cladding. Rather than using unalloyed zirconium, this invention utilized for a 0.1-4% tin alloy liner for the cladding. The very low metallic impurities to reduce solid solution strengthening and second phase formation and property variability from lot to lot, while using alloying to reduce the susceptibility to steam corrosion. Preferably, oxygen is controlled to a very low level as well, to provide a low, but fabricable, hardness in the alloyed liner material.

Abstract: This is a process for producing material for lining reactor fuel element claddings. Rather than using unalloyed zirconium, this invention provides for an alloy liner for the cladding. The process uses ultra-slow electron beam melting of zirconium, to give very low metallic impurities to reduce solid solution strengthening and second phase formation and property variability from lot to lot, while using alloying to reduce the susceptibility to steam corrosion. Oxygen is controlled to a very low level as well, and preferably only 0.1-0.4 tin is added to provide a low, but fabricable, hardness in the alloyed liner material.

Abstract: This is a process for producing material for lining reactor fuel element claddings. Rather than using unalloyed zirconium, this invention provides for an alloy liner for the cladding. The process uses electron beam melting of zirconium, to give very low metallic impurities to reduce solid solution strengthening and second phase formation and property variability from lot to lot, while using alloying to reduce the susceptibility to steam corrosion. Preferably, oxygen is controlled to a low level as well, to provide a low, but fabricable, hardness in the alloyed liner material.

Abstract: A filter cleaning process for filters for separating particulates from a hot gas stream using hollow, tubular filter elements. Blowback and hot purge gas systems provide for cleaning of the filter elements and maintenance of the blowback system clear of the solids or condensation products that might form during separation. The process is especially useful in filtering solids from a hot, corrosive gaseous stream, such as a zirconium tetrachloride process gaseous stream, where the gas stream contains gaseous constituents that are subject to condensation directly to a solid during separation of the particulates and prior to discharge from the filtering apparatus.

Abstract: This is an improved electrode for consumable vacuum arc melting of zirconium and titanium alloys, for alloys containing a low melting point alloying material or for very low oxygen zirconium. Electrodes of this type use a low resistance spar extending substantiallly the length of the electrode, with this spar being substantially free of any unalloyed low melting point material. The improvement utilizes attachment by wedging of the external members to the spar core. Preferably the wedging is accomplished by rotation of the external member with respect to the spar core.

Abstract: This is a molten salt extractive distillation process for separating hafnium from zirconium. It utilizes at least principally a ZnCl.sub.2 --Ca/MgCl.sub.2 molten salt solvent, and preferably ZnCl.sub.2 --Ca/MgCl.sub.2 in a near 95-15 mixture. The extraction column is preferably run about 380.degree.-420.degree. C. at about one atmosphere and stripping is preferably done at about 385.degree.-450.degree. C. utilizing an inert gas carrier.

Abstract: A process for etching zirconium metallic articles using an aqueous bath of hydrofluoric acid and nitric acid wherein the active hydrofluoric and nitric acid contents of the bath are determined by measurement of the dissolved zirconium content of the bath, and the bath is replenished in acid to give substantially the active hydrofluoric acid concentration and ratio to nitric acid, without removal of dissolved zirconium from the bath, to increase the bath etching life.

Abstract: This is a molten salt extractive distillation process for separating hafnium from zirconium. It utilizes at least principally a ZnCl.sub.2 -PbCl.sub.2 molten salt solvent, and preferably ZnCl.sub.2 -PbCl.sub.2 in a near eutectic or eutectic mixture. The extraction column is preferably run about 370.degree.-390.degree. C. at about one atomosphere and stripping is preferably done at 375.degree.-400.degree. C. utilizing an inert gas carrier.

Abstract: Transition metal, notably zirconium alloy, is melted (e.g., by a plasma) to form droplets within the size range of minus 20, plus 60 mesh. The droplets are exposed to a hydrogen atmosphere for a short period while cooling through the hydriding temperature range (e.g., 600.degree. C. to 400.degree. C.). A friable particulate of uniform size and hydrogen content, suitable for sintering or forming components, is recovered.

Abstract: Hydrocarbon fuel is combusted in a combustion turbine by a method which produces NO.sub.x emmissions below an ultra-low standard. In the method, first, a mix of hydrocarbon fuel and air in a primary flow thereof is burned in a primary combustion zone so as to produce a flow of hot gas of a temperature above that required for an efficient catalytic reaction and which contains NO.sub.x at levels below a low standard but above the ultra-low standard. Next, the hot gas is mixed with hydrocarbon fuel in a secondary flow thereof in a mixing and vaporization zone to provide a flow of heated fuel mixture of a temperature above that required for an efficient catalytic reaction. Thereafter, the heated fuel mixture is inefficiently catalytically reacted in a first catalytic element fuel to provide a flow of effluent gas of a temperature above that required for an efficient catalytic reaction and which contains NO.sub.

Abstract: This is a high quality zirconium or hafnium sponge, a fuel element cladding liner having material of the quality of this sponge and a process utilizing this quality sponge to fabricate liner material for lined fuel element cladding. The sponge contains 250-about 350 ppm of oxygen impurity, 50-300 ppm of iron impurity, and a total of 500-1,000 ppm of impurity. This material is much purer than conventional sponge and approaches the quality of crystal bar.

Abstract: Processes for the rapid alpha annealing of zirconium based articles are described. These processes utilize induction heating to rapidly heat a worked zirconium based article to an elevated temperature after which it is then cooled. Time at the selected elevated temperature is less than about 1 second, and preferably essentially zero. Stress relieving of cold pilgered Zircaloy may be performed by induction heating to a temperature between about 540.degree. and about 650.degree. C. Partial recrystallization annealing of cold pilgered Zircaloy may be performed by induction heating to a temperature between about 650.degree. and about 760.degree. C. Full alpha recrystallization annealing of cold pilgered Zircaloy may be performed by induction heating to a temperature between about 760.degree. and about 900.degree. C.

Abstract: A process for distilling zirconium sponge in an iron containing vessel at a temperature sufficiently low to preclude iron contamination of said sponge is disclosed. A distillation temperature near about 934.degree. C. is sufficiently low to minimize iron contamination while being sufficiently high to cause sintering of the sponge to a degree that subsequent comminution does not produce excessive fines.

Abstract: This invention identifies methods and articles designed to circumvent metallurgical problems associated with hermetically closing an all cast iron nuclear waste package by welding. It involves welding nickel-carbon alloy inserts which are bonded to the mating plug and main body components of the package. The welding inserts might be bonded in place during casting of the package components. When the waste package closure weld is made, the most severe thermal effects of the process are restricted to the nickel-carbon insert material which is far better able to accommodate them than is cast iron. Use of nickel-carbon weld inserts should eliminate any need for pre-weld and post-weld heat treatments which are a problem to apply to nuclear waste packages.

Abstract: A solid solution, nonmagnetic, austenitic nickel base alloy class is described. It contains: about 12 to 21 weight percent chromium; a concentration of molybdenum and/or tungsten, such that the sum of the weight percent molybdenum and one third the weight percent tungsten present is between 1 and 7 weight percent and wherein the w % tungsten is less than 12 w %; about 4 to 13 w % iron; small but effective amounts of the desulfurizing agent, manganese; and up to about 2.5 w % silicon. Carbon may be present at levels up to 0.15 w % and cobalt may be present at levels up to 2 w %. The above elements are balanced to provide alloys having a mean thermal expansion coefficient, .alpha..sub.(RT-T), for T.ltoreq.1000.degree. F., of less than 8.3.times.10.sup.-6 in./in./.degree.F., and preferably less than 8.times.10.sup.-6 in./in./.degree.F.In addition, a precipitation hardening, non-magnetic, austenitic nickel base alloy class is also described.

Abstract: This is a process for producing high quality zirconium or hafnium sponge. It is especially useful for producing the very high purity zirconium which may be used to line the inner surface zirconium of Zircaloy tubing for nuclear fuel rods. The process uses a combination reduction-distillation vessel which is directly fed with zirconium or hafnium tetrachloride from a molten salt sublimer. A precharge of magnesium chloride is used to prevent reduction of metal outside the inner liner, and thereby facilitate removal of the inner liner after reduction and distillation. The agitator for the molten salt sublimer preferably utilizes a molten metal seal around the agitator shaft.

Abstract: Described herein are alpha zirconium alloy fabrication methods and resultant products exhibiting improved high temperature, high pressure steam corrosion resistance. The process, according to one aspect of this invention, utilizes a high energy beam thermal treatment to provide a layer of beta treated microstructure on an alpha zirconium alloy intermediate product. The treated product is then alpha worked to final size. According to another aspect of the invention, high energy beam thermal treatment is used to produce an alpha annealed microstructure in a Zircaloy alloy intermediate size or final size component. The resultant products are suitable for use in pressurized water and boiling water reactors.