Return to DOE Reports Table of Contents A-H

Return to Advanced Hot Gas Filter Development Reports Table of Contents

Advanced Hot Gas Filter Development Topical Report
Reporting Period:  May 1995 January 1999

Hurley, John L.  (Deceased)
June,  Matthew R.
Johnson, Mark W.

Pall Corporation

Part 1, Pages 1 - 81, 3.80MB
Part 2, Pages 82 - 127, 3.62MB
Part 3, Pages 128 - 180, 4.92MB
Part 4, Pages 181 - 226, 5.04MB

Table of Contents

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