Multi Functional Metallic and Refractory Materials

Objective:

The primary objective of this project is to develop multifunctional metallic and refractory materials for energy efficient handling of:

  1. Molten Aluminum
  2. Molten baths (zinc and zinc-aluminum alloys) for steel coating
  3. Superalloys containing chromium, cobalt and nickel

The project is funded by U.S. DOE Office of Industrial Technologies, Industrial Materials of the Future Solicitation. The Industrial Technologies Program works with U.S. industry to improve industrial energy efficiency and environmental performance. The program invests in high-risk, high-value research and development to reduce industrial energy use while stimulating productivity and growth. The total project budget for three years of $5,682,788. Agency funding is $2,909,925. Industry partners will provide $2,162,000 cost-share in cash contributions, in-kind goods, and services, while WVU will provide the remaining cost share.

Start date: March 2004
Anticipated end date: November 2007

Several WV Industries will benefit directly, including Steel, Steel coating, Specialty Metals, Metal Casting, Aluminum and other related industries.

Partners:

AK Steel Corporation-Research
Allied Mineral
Blasch Precision Ceramics
California Steel Industries, Inc.
Deloro Stellite
DOE Golden Field Office
DOE Headquarters
Duraloy Electroalloys
Emhart Glass
Fireline TCON
Harbison-Walker Refractories Company
ISPAT Inland Steel
Kyanite Mining
Magneco/Metrel
Metaullics Systems Co.
Missouri Refractory Co.
Nucor – AR
NUCOR – SC
Nucor – Ind
Oak Ridge National Lab
Pechiney Rolled Products
Praxair Surface Technologies, Inc.
Special Metals
Sturm Rapid Response Center
Teck Cominco
The Techs
Thermal Ceramics
UMR
US Steel Research
Vesuvius McDanel
Vesuvius Monofrax
Wheatland Tube Co
Wheeling-Nisshin
Worthington Steel

Industrial Organizations:

EIO: Energy Industries of Ohio
ILZRO: International Lead Zinc Research Organization, Inc.
SECAT

Researchers:

Ever J. Barbero, PI, WVU
Bhaskaran Gopalakrishnan, WVU
Bruce Kang, WVU
Xingbo Liu, WVU
James Hemrick, ORNL
Vinod Sikka, ORNL
William L. Headrick, UMR, (573) 341-4188
Musa Karakus, UMR, (573) 341-4120
Jeff D. Smith, UMR, (573) 341-4447
Carl Irwin, NRCCE

Students:

Mark Bright
Raviraj Chavan
Shalini Rangarajan
Jing Xu
Adam Ensminger
Ashok Varadarajan
Devdutt Shukla, UMR, (573) 341-4188, Ph.D. Candidate
Eric Feiner, UMR, (573) 341-4188, Undergraduate Research Assistant
Andrea Krive, UMR, (573) 341-4188, Undergraduate Research Assistant

Staff:

Kathleen Cullen (304) 293-2867 ext 5426
Mike Carr (304) 293-4607 ext 2370

Accomplishments:

WVU Dross Tester: Laboratory scale corrosion research on current and newly developed materials has led to an understanding of the dynamic corrosion and dross formation that occurs on steel galvanizing rolls. See DoE ITP E-bulletin http://www.eere.energy.gov/industry/imf/pdfs/corrosionresistant.pdf  (April 2006)

 

 

 

 

WVU ½-scale Prototype Tester: A laboratory device has been constructed that permits evaluation of wearing, dross build up, and other hardware. The device mimics the operation of a molten metal coating  bath of a typical industrial line. Prototype is evaluated while submerged in molten metal and subjected to conditions similar to those encountered in industrial lines.

 

 

 

ORNL Infrared Thermal Conductivity Tester: A laboratory devise was constructed and testing methodology was developed for measuring the thermal conductivity of various refractory materials beign developed in this project. Materials that thermodinamically show promise as insulators are then tested to determine their actual conductivity.

 

 

 

ORNL Sessile Drop Wetting Angle Tester: A laboratory devise was constructed and testing methodology was developed for measuring the contact angle between molten metals and various substrates beign developed in this project. Materials that thermodinamically show promise as non-wetting are then tested to determine their actual wetting angle under static conditions.

 

 

 

 

ORNL Dynamic Sessile Drop Wetting Angle Tester: A laboratory devise was constructed and testing methodology was developed for measuring the contact angle between molten metals and various substrates beign developed in this project. Materials that thermodinamically show promise as non-wetting are then tested to determine their actual wetting angle under dynamics conditions.

 

 

Galvanizing Energy Profiler Decision Support System (GEPDSS): A New Decision Support System Model Identifies Opportunities for Energy Savings in Steel Coating Lines based on improvements in pot hardware characteristics and energy consuming equipment on the galvanizing lines. A multilayered engineering-based energy evaluation model was developed. This model quantitatively determines energy and productivity benefits resulting from the implementation of new pot hardware materials in galvanizing lines. The model has been validated and demonstrated to report estimated galvanizing line energy consumption accurate within 5% of actual energy consumption in several galvanizing lines of industrial partners and accurately estimates in variances in production and energy consumption with respect to changing line equipment characteristics. See DoE ITP E-bulletin http://www.eere.doe.gov/industry/imf/pdfs/multi_func_mats.pdf (July 2006)

Weld Overlay : This novel material has been successfully tried in laboratory and passively in production lines. Further development is expected. The photo shows the difference between bare stainless steel (at right) and steel coated with the new material (at left) when exposed to a zinc bath for 81 days -- similar to conditions to which metal processing hardware and containers are exposed in an industrial setting. The bare steel side shows extensive corrosion and dross buildup, while the steel coated with the new material shows very little corrosion and dross buildup.

DoE ITP Highlights:

April 2006: http://www.eere.energy.gov/industry/imf/pdfs/corrosionresistant.pdf

July 2006: http://www.eere.doe.gov/industry/imf/pdfs/multi_func_mats.pdf

Other Links:

http://iofwv.nrcce.wvu.edu/indexcrosscut.cfm
http://www.eere.energy.gov/industry/resources/ebulletin/
http://www.cemr.wvu.edu/news/news-details.php?item=628