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ORNL P
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11:123333
|1:25 14 LE
MICROCOPY RESOLUTION TEST CHART
NATIONAL BUREAU OF STANDARDS -1963
TORNE 13138
Conf-660456--1
8 MASTER
CFSI) PRICES
FUN 2 2 1969
Ho$2.00; MN_,651
HIGH-PURITY SHAPE CASTING WITH AN ELECTRON-BEAM FURNACE*
C. W. Dean, R. E. McDonald, and C. F. Leitten, Jr.**
Metals and Ceramics Division
Oak Ridge National Laboratory
Oak Ridge, Tennessee
ABSTRACT
An electron-beam melting furnace has been utilized to produce
laboratory quantities of high-purity metals for many Oak Ridge National
beth
Laboratory research programs. The furnace hearth originally produced
L
e
pancake-shaped ingots. Although high-purity samples could be produced in
this shape, they contained cold shuts, porosity, and a coarse grain struc-
ture. Because of the shape and other undesirable properties, rod and wire
were difficult to produce from such castings.
To overcome these difficulties, we developed a casting technique
PANTE
.
that permitted a molten charge of high-purity metal to be arop cast into
a cylindrical or rectangular chill mold. Subsequent fabrication was easier
and less expensive because of the improved cast structure and more desirable
( . .
Rudi
.
ingot shapes.
In addition, a higher material yield was realized. The drop-
casting technique and melting equipment have been used to cast fabricable
2
shapes of Ti, Zr, ib, V, Ta, W, Mo, and their alloys.
...
*Research sponsored by the U.S. Atomic Energy Commission under contract
with the Union Carbide Corporation.
**Now with Union Carbide Corporation, Lindé Division.
DISTRIBUTION QE THIS DOCUMENT IS UNLIMITED
KAL
***********
-----
--------..
co
+
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.
.
.
AL
I

INTRODUCTION
F
.
The type or research programs at the Oak Ridge National Laboratory
requires a casting and melting capability for a variety of metals.
Because certain impurities can be vaporized during the melting operation
and because there is no contamination from molds or electrodes, the electron-
+
WIE
beam furnace is useful for producing many metals and alloys of extremely
high purity. In the routine melting of most refractory metals ac ORNL,
melts are produced with a very low interstitial impurity content. By
***
remriting several times before final casting is attempted, homogeneity is
a
.
achieved on the high melting point, difficult-to-alloy metals.
This report
$
med
covers the development of a drop-casting technique that greatly improved
PAP
at
the fabricability of the electron-beam melted alloys.
EXPERIMENTAL
Equipment Design
The electron-beam furnace employed in this study is an original NRC
design that has undergone considerable modification by ORNL. Although
originally designed with one electron gun and one hearth, this furnace
is now equipped with two electron guns and hearths. Figure 1 shows the
configuration of the furnace before modification, and Figure 2 shows the
furnace after modification.
The double-gun anà -hearth configuration
allows two melts to be made without opening the furnace.
LEGAL NOTICE
This report was prepared as an account of Government sponsored work. Neither the United
States, por the Commission, nor any person acting on behalf of the Commission:
A. Makes any warranty or representadon, expressed or implied, with respect to the accu-
racy, completeness, or usefulness of the information contained in this report, or that the use
of any information, apparatus, method, or process disclosed in this roport may not Infringe
privately owned righta; or
B. Assumes any liabilities with rospect to the use of, or for damages resulting from the
ase of any information, apparatus, method, or process disclosed in this report,
As used in the above, "person acting on behalf of the Commission" includes any em-
bloyee or contractor of the Commission, or employee of such contractor, to the extent that
uch employee or contractor of the Commission, or employee of such contractor prepares,
lisseminatos, or provides acco&o to, any faformation pursuant to his employment or contract
ith the Commission, or his employment with such contractor,
The cylindrical furnace shell is constructed of 1/2-in.-thick
stainless steel plate with a 23 in. inside diameter and a 60 in. length.
The evacuation system consists of two 10-in. diffusion pumps, a.
5 hp-30 cfm roughing pump, and two 1 hp-30 liter/min backing pimps and is
capable of reducing the internal pressure to 1 x 10°° torr in approximately
20 min. Unless high outgassing rates are encountered during metal purifi-
cation, this evacuation system is capable of maintaining a pressure of
5 x 10-0 torr throughout the melting cycle. Each gun chamber has a separate
4-in. short-series diffusion pump that evacuates the chamber to 5 x 10-7 torr.
A measure of the removal of interstitial impurity elements is shown
by the chemical analysis in Table 1.
The furnace is rated at 60 kw (20,000 v and 3 amp) which is adequate
power for melting most refractory metals and alloys. Cathodes are machined
from electron-beam melted T-111 (Ta-8 wt% W—2 wt % Hf) alloy. They are
approximately 1 in. in diameter and 1/8 in. thick and have a concave face,
for initial focusing, that is polished to a very smooth finish.
?
.
To accelerate cooling and minimize contamination, melts are made in
.
a variety of water-cooled copper molå shapes, which consist of four besic
designs: for initial consolidation ană purification – pancake, button,
and finger; and for final casting - either rectangular or cylindrical drop-
casting molds. Figure 3 shows some of the molds in use. A button mola
is designed specifically for drop casting and is split in half for easy
removal from the skull that remains after casting. A 1/2- to l-in.-dian
hole is bored through this mold to permit the metal to flow rapidly into a
.

drop-casting mold. The drop-casting apparatus consists of a cylindrical
copper mold that is 2 in. OD and 3 1/2 to 6 1/2 in. in length. This mold
is split to facilitate removal of the ingot and is clamped together for
casting,
Drop-Casting Procedure
The original furnace design and associated hearths permitted the
melting of only pancake shapes approximately 4 in. in diameter by 3/4 in.
thick. Such ingots, however, were not readily amenable to fabrication
casting arrangement. Demands for high-quality rod and wire products neces-
sitated the development of an electron-beam melting technique capable of
producing ingot shapes amenable to swaging and wire-drawing operations.
The result was a technique which we refer to as drop casting. Drop
casting differs in many respects from what is commonly referred to as "drip
casting." In drip casting the material is melted in a button hearth with a
hole in the bottom in such a manner that the molten metël ruins slowly into
VA
the vertical mold below.
This produces an irregular surface and an inhomo-
geneous internal condition.
In order to make a drop casting, scrap and/or chop stock is first
melted in a conventional button mold. By turning the button from side to
side and remelting several times, homogeneous alloying is achieved even for
the most hard-to-melt, difficult-to-alloy refractory metals. When consolida-
tion, purification, and homogeneity of the melt are assured, the button mold
is removed and the drop-casting apparatus is installed.
The electron beam, broadly focused, traverses the button until the
button surface is completely molten. The beam is now "pinpointed" or
concentrated while continuing to traverse the molten surface. The button
now melts to deeper penetrations until the entire charge is molten except
for a thin layer at the bottom. An increase in furnace power rapidly melts
the bottom of the button and the molten metal is drop cast into the vertical
chill mold.
RESULTS AND DISCUSSION
The rapid drop-casting action prevents cold shuts and gives an
internally sound ingot with good surfaces. Because of the differential
cooling rate from top to bottom, pancakes and buttons usually contain
shrinkage cavities. In a drop casting, the body of the ingot solidifies
at a greater rate than does the feeder head. This solidification sequence
results in the elinination of shrinkage cavities from the body of the ingot.
The internal structure of pancakes and drop castings differs in many
respects. Pancale configurations generalîy exhibit a fine-grained structure
at the bottom and a much coarser grain structure at the top, because of
the vast differences in solidification and cooling rates exhibited within
these regions. The microstructure of a molybdenum pancake, illustrated in
Fig. 4, shows the definite line of demarcation that exists between the grain
sizes. In addition, grains extend through the entire thickness of some
pancakes. Drop-cast ingots are internally homogeneous and exhibit a uniform.
grain size throughout, as shown in Fig. 4 for molybdenum.

Not only do drop castings have a more desirable grain structure for
fabrication but they are also in a configuration that is much easier to
fabricate. A cylindrical drop casting is readily amenable to swaging and
drawing operations, while sheet, plate, or bar are easily fabricated from
ingots having rectangular cross sections. Fabrication of rod or wire from
pancake configurations requires a costly cutting operation. Further diffi-
culties are encountered because the sectional strips are rectangular and
contain a broad range of grain sizes and therefore are not readily amenable :
to the formation of cylindrical shapes. For many refractory metals this
sectioning operation is not practical because of breakage during cutting
operations.
Fabricavility improvements afforded by drop casting are also accom-
panied by a considerable gain in material yield. An average yield for drop-
cast ingots is approximately 80% in the ingot condition, but almost 100%
yield is attained on fabrication. A drop casting must be overcharged by
almost 100% yield on melting, but on fabrication the average yield is
considerably lower. ;
Ingots up to 3/4 in. in diameter and 5 1/2 in. long of V, N., Mo, Zr,
Ti, and Nb-1% Zr are routinely drop cast. Refractory alloys such as
W-26 at. % Re, 6–35 at. % Re-18 at. % Mo, and Ta-20% W have been successfully
drop cast in ingots 1/2 in. in diameter and 2 1/2 in. in length. Figures 5
and 6 show a number of these castings.'
CONCLUSIONS
The quality of electron-beam melted drop-cast materials is superior
20 that produced by other methods. The low impurity levels combined with
the favorable grain structure obtained by drop casting improves alloy
fabricability. In addition, the shapes of the drop-cust ingots are readily
amenable to fabrication methods such as swaging, rolling, and wire drawing.
Table 1. Chemical Analysis of Interstitial. Impurities
Before and After Electron-Beam Melting
Material
C
270
.
Before, ppm
o H
200 1090 45
710 4
400 1260 8
80 1300 60
40 75 2
40 25 5
30 20 3
30 71 23
20 29 6
Titanium
Molybdenum
Vanadium
Zirconium
Niobium
Tantalum
Tungsten
N-1 ut % Zr
Ta–10 wt% W
W-26 at. % Re
N
340
6
720
25
45
12
5
36
5
V
After, ppm
o Ha N.
890 <1 260
20 < 2 <2
880 € 570
630 2 24.
38 2 10
12 3 4
5 <2 <2
10 10 15
21 4 3
59 5 18
c
3.60
< 20
220
50
< 20
30
< 20
30
< 20
< 20
W
v
FIGURES
Fig. 1 (62940) Electron-Beam Furnace Original Configuration.
Fig. 2 (ORNL Photograp)2 87405) Electron-Beam Furnace Modified
Configuration.
Fig. 3 (ORNL Photograph 67502) Electron-Beam Furnace Drop-Casting
Molds.
WW
Fig. 4 (Y-77190, Y-78944) Top - Electron-Beam Melted Molybdenum
Pancake. Bottom – Electron-Beam Melted Molybdenum Drop-Casting. Original
Magnification: 3x. Etchant:
Fig. 5 (ORNL Photograph 87073) Electron-Beam Melted Cylindrical
W
.Indian
MU
NR
Drop Castings.
Fig. 6 (ORNI Photograph 87072) Electron-Beam Melted Rectangular
...:
Drop Castings.
.

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