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Failure Analysis of Gas Spray Atomization Crucible Materials

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Abstract

An attempted induction melt for gas spray atomization of a Pd alloy at Savannah River National Laboratory experienced a series of faulty thermocouple readings leading to failure of multiple alumina ceramic components and the loss of the metal charge. The spherical powders are used in the research and development efforts for hydrogen storage applications. The failure of the thermocouples led to high operating temperatures exceeding the expected operating temperatures. Estimated temperatures of the liquid metal were established by the comparison of the radio frequency power output and multiple temperature readings and determined to have exceeded the functional temperature range of the alumina components. Failure analyses of the event included characterization of the components using visual observation and X-ray computed tomography of the frozen ingot.

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Acknowledgements

Ken Imrich for performing the electrical discharge machining of the ingot and Kenn Gibbs for performing the X-Ray and CT imaging.

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Authors and Affiliations

  1. Savannah River National Laboratory, Aiken, SC, USA

    A. J. McWilliams, A. J. Duncan, L. N. Ward & A. A. Rodriguez-Vaquer

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  1. A. J. McWilliams
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  2. A. J. Duncan
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  3. L. N. Ward
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  4. A. A. Rodriguez-Vaquer
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Correspondence to A. J. McWilliams.

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McWilliams, A.J., Duncan, A.J., Ward, L.N. et al. Failure Analysis of Gas Spray Atomization Crucible Materials. J Fail. Anal. and Preven. 20, 882–887 (2020). https://doi.org/10.1007/s11668-020-00887-w

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  • DOI: https://doi.org/10.1007/s11668-020-00887-w

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