|
1.0 |
Executive Summary |
1 |
|
2.0 |
Introduction |
2 |
|
3.0 |
Procedure |
3 |
|
3.1 |
Manufacture of Seamless Iron Aluminide |
3 |
|
3.1.1 |
Selection of Alloy Compositions |
3 |
|
3.1.2 |
Forming a Non-sintered (Green) Tube |
3 |
|
3.1.3 |
Sintering |
4 |
|
3.1.4 |
Machining |
4 |
|
3.1.5 |
Welding |
4 |
|
3.2 |
Short-Term Exposure Tests |
5 |
|
3.2.1 |
Corrosion Test Apparatus |
5 |
|
3.2.2 |
Blowback Testing |
5 |
|
3.2.3 |
Test Atmosphere |
5 |
|
3.2.4 |
Test Procedure |
6 |
|
3.3 |
Long-Term Exposure Test |
6 |
|
3.4 |
Manufacture of Fifty Filters |
7 |
|
3.5 |
Property Testing |
7 |
|
3.5.1 |
Non-Destructive Testing |
7 |
|
3.5.1.1 |
Mass |
7 |
|
3.5.1.2 |
Pressure Drop |
7 |
|
3.5.1.3 |
Bubble Points |
7 |
|
3.5.1.4 |
Visual Inspection |
8 |
|
3.5.2 |
Destructive Testing |
8 |
|
3.5.2.1 |
Carbon/Sulfur |
8 |
|
3.5.2.2 |
Oxygen/Nitrogen |
8 |
|
3.5.2.2 |
Ring Burst Test |
8 |
|
3.5.2.3 |
Ductility |
9 |
|
3.5.2.4 |
Pore Distribution |
9 |
|
3.5.2.5 |
Surface Area |
9 |
|
3.5.2.6 |
Scanning Electron Microscope Examination |
9 |
|
4.0 |
Results and Discussion |
9 |
|
4.1 |
Manufacture of Seamless Iron Aluminide |
9 |
|
4.1.1 |
Selection of Alloy Compositions |
9 |
|
4.1.2 |
Forming a Non-sintered (Green) Tube |
10 |
|
4.1.3 |
Sintering |
10 |
|
4.1.4 |
Machining |
11 |
|
4.1.5 |
Welding |
11 |
|
4.2 |
Short-Term Exposure Tests |
11 |
|
4.2.1 |
Non-Destructive Test Results and Discussion |
12 |
|
4.2.1.1 |
Mass |
12 |
|
4.2.1.2 |
Pressure Drop |
13 |
|
4.2.1.3 |
Bubble Points |
13 |
|
4.2.1.4 |
Visual Inspection |
14 |
|
4.2.2 |
Destructive Testing |
14 |
|
4.2.2.1 |
Carbon/Sulfur |
14 |
|
4.2.2.2 |
Oxygen/Nitrogen |
14 |
|
4.2.2.3 |
D-Ring Tensile Test |
15 |
|
4.2.2.4 |
Ring Burst Test |
15 |
|
4.2.2.5 |
Ductility (Ring Crush Test) |
15 |
|
4.2.2.6 |
Scanning Electron Microscope Examination |
15 |
|
4.2.2.6.1 |
Control Images |
16 |
|
4.2.2.6.2 |
Exposed Samples from Run 1 – Run 4 |
17 |
|
4.2.2.6.3 |
Exposed Samples from Run 6 |
17 |
|
4.3 |
Long Term Exposure Test |
18 |
|
4.3.1 |
Non-Destructive Test Results and Discussion |
18 |
|
4.3.1.1 |
Mass |
18 |
|
4.3.1.2 |
Pressure Drop |
19 |
|
4.3.1.3 |
Bubble Points |
20 |
|
4.3.1.4 |
Visual Inspection |
20 |
|
4.3.2 |
Destructive Tests |
20 |
|
4.3.2.1 |
Carbon/Sulfur |
21 |
|
4.3.2.2 |
Oxygen/Nitrogen |
21 |
|
4.3.2.3 |
Ring Burst Strength Test |
21 |
|
4.3.2.4 |
Ductility (Ring Crush Test) |
21 |
|
4.3.2.5 |
Pore Distribution |
21 |
|
4.3.2.6 |
Scanning Electron Microscope Examination |
22 |
|
4.3.2.6.1 |
Control Images |
22 |
|
4.3.2.6.2 |
Samples exposed for 500 hours |
22 |
|
4.3.2.6.3 |
Samples exposed for 1000 hours |
23 |
|
4.3.2.6.4 |
Samples exposed for 1500 hours |
23 |
|
4.4 |
Manufacture of Fifty Filters |
23 |
|
4.4.1 |
Quality Control Procedures |
23 |
|
4.4.1.1 |
Traceability of Raw Materials |
23 |
|
4.4.1.1.1 |
Iron Aluminide Powder |
23 |
|
4.4.1.1.2 |
Hardware Materials |
24 |
|
4.4.1.2 |
Product Inspection Methods |
24 |
|
4.4.1.3 |
Processing Instructions |
24 |
|
4.4.1.3.1 |
Raw Materials |
24 |
|
4.4.1.3.2 |
Fabrication of Seamless Cylinders |
24 |
|
4.4.1.3.3 |
Sintering of Media Cylinders |
24 |
|
4.4.1.3.4 |
Qualification Testing of Sintered Medium |
24 |
|
4.4.1.4 |
Bills of Materials |
24 |
|
4.4.1.5 |
Control Drawings |
25 |
|
4.4.2 |
Quality Assurance Tests |
25 |
|
4.4.2.1 |
Dimensional Conformance |
25 |
|
4.4.2.2 |
Media Strength |
25 |
|
4.4.2.3 |
Filter Properties |
25 |
|
4.4.2.3.1 |
Permeability |
25 |
|
4.4.2.3.2 |
Removal Efficiency |
25 |
|
4.4.2.3.3 |
Blowback Performance |
25 |
|
4.4.2.3.4 |
First Bubble Test |
26 |
|
4.4.2.3.5 |
Open Bubble Test |
26 |
|
4.4.3 |
Production of Fifty Filters |
26 |
|
5.0 |
Conclusions |
27 |
|
6.0 |
Recommendations |
27 |
|
7.0 |
References |
28 |
|
8.0 |
Appendices I – IX |
29 |
