Long range aerospace manufacturing developments. Volume II. Base metal forms, forming, material removal, and joining. Report (1968)

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50 PRIORITY RATING WORKSHEET CHART NO PROfiRAM FACTORS PROaRAM PROBABIL ITY OF S U C C E S S a LOW z ^ MODERATe 5 • HiaH 8 C R I T I C A L P R O B L E M S T O B E S O L V E D X F O ^ / N O T TOO DIFFICULT Z • S O M E / D I F F I C U L T S a M A N Y / VERY PIFPICULT 8 P R O C E S S C R O W T H P O T E N T I A L X L ITTLE OR UNDEFINABLE O • gecosmmate pereuTiAi. 4- A P P L I C A T I O N S O T H E R T> IAN A I R I V R C E • NONE O X SOME 4 D MANY e N E C E S S I T Y F O R A I R F O R C E F U N D I N S n LOW HiaM iHiaSTav/cTHCA <So<fr CFFtxir • X M»OHATE - SONf EFMLT OTHce 'SMAJCS 8 a tlC£UIS\¥£ Alt. F«ft£L FUMP H6 UKSLI \X 9 Pa NEED FACTORS S Y S T E M S P R O B A B I L I T Y HiaH PBOBABI ITY \Z FAIR P R O B A B I L I T Y 8 LOW P R O B A B I L I T Y 4 COMPONENT C R I T I C A L I T Y VeBV HKTH I I H I 6 H 9 FAIR 6 L o w 3 F R E 4 U C N C Y OF REQUIREMENT IN S Y S T E M Mene T H A N 3 C O M P » * I E N T 9 3 2 3 CeMPeMEMTS 2 S I N G L E C O M P O N E N T I o e s \ G N A L T E R N A T E S No ALTERNATe R M E B C E N '> ONE ALTERMATe 6 S E V E R A L ALTERMATe« 3 M A T E R I A L S IMPLICATION NEW MATERlflL P e y e u i f M t N T RCA O 6 MATtKlAL IMPHOVEMtNT R E A P 4 NO P R o e L E M F o K c s e e k i o CALCULATE PRIORITY. STEP I C I R C L E HIGHEST AARP RAW S C O R E n s STEP Z IN EACH CTTHER SYSTEM C I R C L E N E X T H I C H E S T S C O R E IF WITHIN 4 POINTS OF TOP SCORE n" NUMSER OF SYSTEMS HldH ^ LOW STEP 3 CIRCLE FRCOUENCY DISTRIBUTION FACTOR f" BELOWt NuMSeiL ov s y s r e M S HiQH R A W Sco«es FOR EACH REFceeMOP CotwoHttn IN TABLES AT tND or PAMEl IZEPOtT W I T H VtM T O T A L S ENTERCP IN AT CI6UT SYSTEMS 25- AARP RAMti SCORES • • • • • • • • ! [ • • • [ • • • ] [ • • • • • • • • • • • • • • I ] • • • [ 1L NUMBER OF S Y S T E M S LOW I 2 RMMte 1 a I 4 1 1 1 3 1 1 £ 1 *»• 1 4 p = n » f = TOTAL= PRIORITY ®

-51- TITLE PRECISION FORGING REFRACTORY ALLOY TURBINB COMPONENTS FOR MAIN PROPULSION DEVICES CHART N O ILL PRIORITY JZZZl R E L A T E D C A M R C H A R T S : OA MANUFACTURING REQUIREMENT and To p r e c i s i o n f o r g e r e f r a c t o r y a l l o y t u r b i n e d i s c s t u r b i n e blades t u r b i n e vanes a f t e r b u r n e r f l a p s f o r t u r b o j e t and t u r b o r o c k e t advanced main p r o p u l s i o n d e v i c e s The t u r b i n e d i s c s would be up t o 30 inches diameter and 4 inches t h i c k w i t h a t o l e r a n c e o f + 0 05 per c e n t Blades would be up t o 10 inches long t o a t o l e r a n c e o f + 0 005 0 000 inc h w i t h c o o l i n g passages o f a p p r o x i m a t e l y 0 030 i n c h diameter I n c o r p o r a t e d A f t e r b u r n e r f l a p s would be about 1 i n c h t h i c k w i t h an area o f about 3 square f e e t t o a t o l e r a n c e o f + 1 perc e n t and shapes c o u l d be i r r e g u l a r AARP REFERENCES PftFVPS Chart . Base Met a l Forms No 5 (p 517) APPLICABLE PROCESS 2 01 01 01 Code 01 02 03 CLOSED DIE FORGING HAMMER PRESS OR HIGH ENERGY RATE FORGING 2 2 STATE O F THE ART ASSESSMENT T h i s c h a r t i s an e x t e n s i o n o f Chart No 110 t o p r o v i d e r e f r a c t o r y a l l o y t u r b i n e d i s c s w i t h the a d d i t i o n a l r equirement t h a t they c o n t a i n i n t e g r a l l y f o r g e d c o o l i n g passages C o o l i n g passages are u s u a l l y d r i l l e d i n t u r b i n e d i s c s These are r a d i a l and extend through the blades D r i l l i n g t e chniques have been Improved so t h a t passages can be put i n a l l o y s which are q u i t e d i f f i c u l t t o machine I t I s a n t i c i p a t e d t h a t c o o l i n g passages can be put i n t o the d i s c s i n the f o r g i n g process I n d i c a t i o n s o f success have been o b t a i n e d i n the developmental programs now being c a r r i e d o u t on I n t e g r a l l y bladed wheels o f s u p e r a l l o y s T h i s same technique can be extended i n p r i n c i p l e t o r e f r a c t o r y metals but an e x t e n s i v e program w i l l be r e q u i r e d t o accomplish t h i s advance The u s u a l technique i n f o r g i n g I n t e g r a l c o o l i n g passages i s t o d r i l l e s s e n t i a l l y r a d i a l holes i n the upset d i s c These are packed w i t h bars or w i t h some loose substance such as a r e f r a c t o r y ceramic or another metal These cores are e x t r a c t e d a f t e r c o m p l e t i o n o f f o r g i n g C R I T I C A L P R O B L E M S 1 A l l o f those g i v e n on Chart 110 p l u s 2 Development o f a s u i t a b l e m a t e r i a l f o r p l u g g i n g d r i l l e d h o l e s i n preforms which w i l l m a i n t a i n dimensions o f the holes t h r o u g h subsequent f o r g i n g o p e r a t i o n s and w i l l be r e a d i l y e x t r a c t a b l e ALTERNATE PROCESSES NONE Code

- 3 2 - CHART N O / / / PROPOSED DEVELOPMENT PROGRAM OBJECTIVE To make f o r g e d t u r b i n e d i s c s o f r e f r a c t o r y a l l o y s w i t h I n t e g r a l l y f o r g e d c o o l i n g passages BACKGROUND T h i s o b j e c t i v e has been o b t a i n e d t o a degree and u s i n g more r e a d i l y f o r g e a b l e m e t a l s I n s m a l l d i s c s o f s i m p l e d e s i g n APPROACH The program recommended on Chart 110 should be extended t o develop t h e t e c h n i q u e o f I n t e g r a l l y c o n t a i n e d c o o l i n g passages T h i s does n o t r e p r e s e n t a major e x t e n s i o n D r i l l e d h o l e s i n pref o r m s packed w i t h s u i t a b l e m a t e r i a l can be developed t o a r r i v e a t d e s i r e d f i n a l dimensions A t t h i s stage t h e p a c k i n g m a t e r i a l must be removable and must leave good s u r f a c e i n the passages A l t e r n a t e d e s i g n c o n c e p t s s h o u l d be developed One m i g h t I n v o l v e t h e c o n s t r u c t i o n o f l a m i n a t e d d i s c s c o n t a i n i n g m a t i n g grooves t o f o r m I n t e r n a l passages I n t h e d i f f u s i o n bonded f i n a l p r o d u c t Another concept would u t i l i z e r a d i a l components o f the d i s c each c o n t a i n i n g a b l a d e w i t h an I n t e g r a l s i m p l e c o o l i n g passage Such segments would be assembled and t i e d t o g e t h e r a t t h e c e n t e r o r bonded

53 PRIORITY RATING WORKSHEET CHART PRQgRAM FACTORS P R O f i k A M P P O B A B I L I T Y O F S U C C E S S • L O W ^ MODERATE • H I C H C R I T I C A L P R O B L E M S TO B E S O L V E D D F E W / N O T TOO D I F F I C U L T X 3 0 M E / D I F F I C U L T • M A N Y / V E R Y D IFF ICULT P R O C E S S G R O W T H P O T E N T I A L • L I T T L E OR UNDEFINAOLE K KECOaNliABLE p o r E W T I A L A P P L I C A T I O N S O T H E R T W A N A I R F O R C E • NONE ^ S O M E D M A N Y N E C E S S I T Y F O R A I R z 5 8 2. 5 6 O 4 o e FORCe F U N D I N G • L w HisH m m s i e v / c T H ft 6 w r C F F ftr i<. X . MOOCttATE - SCMt E F r o t T orMOt • S o u M t S 8 • Eic£Li is i^e A I R F o f t c t F U W P « & L I K C L I < I4. NEED FACTORS S Y S T E M S P R O B A B I L I T Y H I G H P B O B A B I I T Y F A m P R O B A B I L I T Y L O W P R O B A B I L I T Y C O M P O N E N T C R I T I C A L I T Y V E R Y H I C H H I < K H F A I R L o w F R E Q U E N C Y OF R E O U I R E M E N r IN - S Y S T E M M O R E THAW 3 C O M P e H E M T S 2. 3 C f i M P o N E N T S S I N G L E C s M P e N E N T DESIGN A L T E R M A T E S No A L T E R N A T e F D a e s E E N O N E A L T E R N A T E S E V E R A L A L T E R M A T E C M A T E C I A L S I M P L I C A T I O N N e w M A r e c i A L p c v <j>fMtMt ee<a o M A T t C l A L i M P A O V t M C N T E £ a i D N O P R O G L E M f o e e s E E U s 4 11 & 3 3 2 I <> 6 3 6 4 o CALCULATE PRIORITY 8 26 R A W S C o f l t S FOR t A C H REFEKtMtrtP IN T A B L K S AT t N P o r P A U E L I J t p O t T W I T H T2AW T O T <LS E N T E C E P nu <30IUIUAI2I/ AT S V S T M S S T E P I S T E P a S T E P 3 3S-C I R C L E U I G H C S T A A R P l? A M S C O R E IN CACH O T H E R SYSXeM C I R C L E N E X T H I C M E S T S C O R E IF W ITHIN POINTS N U M S E R O F - S y s T E W S HldH OF TOP SCORE ^ LOW L. C I R C L E F R E O U E N C Y D I S T R I B U T I O N F A C T O R NuMSen. OP sysrtMS ri sH BE.U3Wt 3 OR Mee.E N U M B E R OF S Y S T E M S L o w 2 R MoBt 1 0 1 a 1 1 1 z 1 *f 1 4 AARP RA>I SCORCS 3Z ZS 2 / \V \ \t¥\\t/ • • m II 1 II 1 • • c z 1 I I I I j i—1 1 I I I I II 1 • n i II 1 • U l 1 — 1 1 — 1 1 I L J 1 1 — ^ 1 1 I I 11 1 I I I I 11 II 1 1 I I I I l U ] i ~ n 1 — 1 1 — 1 1 II 1 11 1 1 I I 1! • • L 11 1 i i ~ i • • d II 1 • • 1 II 1 • • 1 II 1 11 1 TOTAL PRIORITY

54 TITLE POWDER METALLURGICAL PROCESSES FOR FLAT SHEETS AND COMPOSITES FOR NEUTRON RADIATION SHIELDS CHART NO PRIORITY LL2 RELATED CAMR CHARTS OA MANUFACTURING REQUIREMENT Produce f l a c forms for r a d i a t i o n s h i e l d i n g of crew and equipment Sheets for s h i e l d i n g from neutrons are to be as large as 48 x 120 x 0 010 inches Encapsulated metal hydrides would probably be best but other high neutron capture m a t e r i a l s might s u f f i c e Composite m a t e r i a l s with the highest p o s s i b l e i n t e g r i t y w i l l be necessary to f u l f i l l property requirements S h i e l d s must be made to maximum den s i t y and capable of withstanding high temperatures for long times at high r a d i a t i o n l e v e l s (See AARP Report MAB 200 M(AAR 2) for environmental requirement g o a l s ) AARP REFERENCES E Charts 3fL 35 B Char ts . 20a b P i F V P S Char ts . APPLICABLE PROCESS Consolidation (and s i n t e r i n g ) of powders by (A) ROLL COMPACTING (B) EXPLOSIVE PRESSING TO PRODUCE SANDWICH CONSTRUCTIONS (C) COLD PRESSING (D) SPRAYING (E) CASTING J(A)1 03 0§ ( B ) l 03 03 |(C)1 03 02 ( D ) l 03 08 STATE O F THE ART ASSESSMENT A R o l l compacting nould accomplish encapsulating metal hydrides ( L i Y Zr) i n a can and r o l l i n g s i n g l y or i n packs to d e s i r e d d e n s i t y and thickness e i t h e r c o l d or hot Analogous methods have been developed for f u e l c o n t r o l rods used i n nuclear power p l a n t s a l s o canning techniques have been developed for processing r e a c t i v e metals and a l l o y s for vacuum braze bonding and cladding s u p e r a l l o y s to s t e e l R o l l i n g equipment and brazing f a c i l i t i e s are a v a i l a b l e and thought to be adequate Hydrides are b r i t t l e and s e n s i t i v e to handling conditions B E x p l o s i v e p r e s s i n g might be u t i l i z e d to obtain sandwich forms for e i t h e r d i r e c t s i n t e r i n g and brazing Into a composite or for r o l l i n g S i t e s are a v a i l a b l e Methods have already been developed for cladding s u p e r a l l o y s and c o r r o s i o n r e s i s t a n t a l l o y s to s t e e l and/or to each other in sheet forms C Cold p r e s s i n g of powders has been s u c c e s s f u l using i s o s t a t i c pressure on l i t h i u m hydride and could be applied to obtain f i n a l form or form feedstock for machining r o l l i n g and/or s i n t e r i n g P r e s s e s are a v a i l a b l e and adequate Radiation s h i e l d s have been made I n s i z e s up to fourteen Inches diameter (hemispheres) by use of i s o s t a t s to press l i t h i u m hydride powders D Spraying provided a b u i l t up sandwich a m e t a l l i c s u b s t r a t e i n one case aluminum oxide was sprayed on E I n the case of hydrides l i k e l i t h i u m melting approaches may be f e a s i b l e s i n c e the melting points are r e l a t i v e l y low and the hydride might be c a s t onto a su p e r a l l o y sheet I t i s not known whether composites containing hydrides have been made i n t h i s manner CRITICAL PROBLEMS 1 M a t e r i a l s s e l e c t i o n s for c o m p a t i b i l i t y and ease of f a b r i c a t i o n 2 P y r o p h o r i c l t y and hygroscopy of hydrides 3 I n s p e c t i o n and proof t e s t i n g of composite ALTERNATE PROCESSES NONE Code

55 CHART PROPOSED DEVELOPMENT PROGRAM OBJECTIVE To synthesize a minimum weight r a d i a t i o n s h i e l d for p r o t e c t i o n of crew and equipment from r e a c t o r s t r a y neutron r a d i a t i o n BACKGROUND Further s t u d i e s of the p r o p e r t i e s of m a t e r i a l s should be conducted to derive formulations and combinations which w i l l be compatible with a v a i l a b l e f a c l l x t i e s and achieve the d e s i r e d missions As an example the b u i l d i n g of t h i n high I n t e g r i t y gas t i g h t sandwiches (boxes) w i l l r e q u i r e considerable experimental engineering work with candidate m a t e r i a l s to obtain t h i n sheets p o t e n t i a l l y capable of s e r v i n g at high temperatures The mission conditions and environment p r a c t i c a l l y n e c e s s i t a t e a composite m a t e r i a l s design approach Although encapsulated metal hydrides seem to be a p p l i c a b l e for neutron s h i e l d s i t I s doubtful that AARF requirements for high s e r v i c e temperatures and long times can be s a t i s f i e d Ferhaps metal hydride s h i e l d s would have to be held to a maximum per m i s s i b l e temperature by use of thermally p r o t e c t i v e overlays Lithium hydride for example experiences phase changes l i q u e f a c t i o n and high thermal expansion mismatch with encapsulating m a t e r i a l s I t i s not thought that a s i n g l e m a t e r i a l or even a simple sandwich composite can meet a l l of the AARF requirements Powder metallurgy composites warrant i n v e s t i g a t i o n to determine c a p a b i l i t i e s of systems which could be t a i l o r e d to these a p p l i c a t i o n s APPROACH Problem 1 Procedures for compaction and s i n t e r i n g of hydrlded powders re q u i r e optimization for bonding of p a r t i c l e s to each other to give maximum compact density Braze bonding of the core to s u p e r a l l o y sheet covers i s a n t i c i p a t e d and covers must be strong and gas t i g h t Problems of uniformity and r e p r o d u c i b i l i t y must be solved Factors of d i f f e r e n t i a l thermal expansions between d i s s i m i l a r m a t e r i a l s w i l l c r e a t e chances of rupture of p r o t e c t i v e covers and might prevent obtaining maximum density during processing or i n s e r v i c e for the composite Ma t e r i a l s s t u d i e s w i l l be necessary to choose c o m p a t i b i l i t y and to s e l e c t sequence for operations s u i t a b l e for processing during manufacturing of s h i e l d s Equipment for manufacturing i s b e l i e v e d to be a v a i l a b l e for powder r o l l i n g i s o s t a t i c p r e s s i n g powder spraying or explosive forming followed by s i n t e r i n g operations The handling of large t h i n f l a t sheet l i k e composites however w i l l be very d i f f i c u l t and tax the best of present handling f a c i l i t i e s Since a composite m a t e r i a l s system must be developed i t i s recommended that a trade type study be conducted i n i t i a l l y to appraise which composites are best most f e a s i b l e and come c l o s e s t to f u l f i l l i n g mission Problem 2 The s e n s i t i v i t y of handling r e a c t i v e b r i t t l e and hazardous m a t e r i a l s leads one to r e s t r i c t the undertaking of making the required s h i e l d s to experienced laboratory type f a c i l i t i e s therefore A E C s i t e s such as Oak Ridge Los Alamos e t c should be invoked when development program i s e s t a b l i s h e d Problem 3 The checking of uniformity of the f i l l e r or the neutron capture m a t e r i a l over such large areas and i n t h i n s e c t i o n s w i l l present problems i n assurance of freedom from voids and from p o s s i b l e leaks of r a d i a t i o n Conventional Inspection techniques for f l a t products w i l l not be considered adequate and a d d i t i o n a l i n s p e c t i o n methods plus proof t e s t s would be required Development of i n s p e c t i o n and proof t e s t i n g techniques might be accomplished by further study and a p p l i c a t i o n of neutron radiography

55 PRIORITY RATING WORKSHEET CHART P R 0 6 R A M P A C T O R S P R O f i R A M P R O B A B I L I T V O F S U C C E S S D LOW MODEOATe • HlfiiH C R I T I C A L P R O B L E M S TO B E S O L V E O • F E W / N O T TOO PIFFiruLT • S O M E / D I F F I C U L T •>l M A N Y / V E R Y D I F F I C U L T PROCESS GROWTH POTENTIAL X LITTLE OR UNDEFINAOLE • Kecoamzi^BLe POTEMTIAL A P P L I C A T I O N S O T H E R T H A N AIR F O R C E a NONE ; K SOME n M A N Y NECESSITY FOR AIR z 5 8 Z 3 8 o 4 o 6 rORCe F U N D I N O D LOW HieH INDUS e v / c T H e A <io»r CFF «.r H- • tX£UI5l^£ AlR FoRCt FUMPW6 LIKCL-* I t NEED FACTORS SYSTEMS PROBABILITY HIQH P B O B A B l I T Y F A I R P R O B A B I L I T Y L O W P R O B A B I L I T Y C O M P O N E N T C R I T l C A L I T Y V E R Y H IC-H H I A H F A l A L o w FREflUENCY O F BEauiREMENT IN S Y S T E M MeUE THAN 3 C O M P e ^ E M T S 2 3 C e w P e U E M T S S I N f l L E C f M P e N E N T Oes>GN A L T E R N A T E S No A L T E R N A T E R M E S E E N ONE A L T E H N A t e S e v E H A L A L T E R N A T E * M A T E C I A L S I M P L I C A T I O N N e w MATEdiflL ptvtt/jpxtNT ceo O MATECl f lL I M P O O V t M E N T R E S D NO P R O S L E M F o R t S e E K l CALCULATE PRIORITY S T t P I C I R C L E H I G H C S T A A R P R A W S C O R E 6 2S- RAW S C o f l C S FOR EACM K£F£«EHCEI> CoMPONZtfT IN T A f t L U AT t N D OF P A N E t 12tP«tT WITH l l A M TOT \\A E N T E R C P M <3UIUUAtV AT C IGMT S Y S T E M S A A R P R A > M S C O R E S \3S\ n : 55- S T E P 2 S T E P 3 IN EACH OTHER S V S T E M IF WITHIN 4 P O I N T S N U M Q E R C I R C L E OF S y s T E M S HidH C I R C L E NEXT H I S M E S T O F T O P S C O R E n / L O W ^ f R E O U E N C Y D I S T R I B U T I O N F A C T O R NUMQCR. Of SVSTt» / |S H l & H I 2 3 OR Moa.E S C O R E B £ L O W i N U M B E R O F S Y S T E M S L O W 2 B. Moet 1 0 1 a I 4 1 1 1 3 1 4 1 z 1 4 1 4 ! • • [ : [••CZ] o n e • • TOTAL PRIORITY