Background In nuclear fuel plates of low-enriched U-10Mo (LEU) clad with aluminum by hot isostatic pressing (HIP), post-irradiation stresses arising during reactor shutdown are a major concern for safe reactor operations. Measurement of those residual stresses has not previously been possible because the high radioactivity of the plates requires handling only by remote manipulation in a hot cell. Objective The incremental slitting method for measuring through-thickness stress profiles was modified, and a system for automated, remote operation was built and tested. Methods Experimental modifications consisted of replacing electric-discharge machining (EDM) with a small end mill and strain-gauge measurements with cantilever displacement measurements. The inverse method used to calculate stresses was the pulse-regularization method modified to allow discontinuities across material interfaces. The new system was validated by comparing with conventional slitting on a depleted U-10Mo (DU) fuel plate. Results The new system was applied to two measurements each on six as-fabricated (pre-irradiation) LEU miniature fuel plates. Variations between the measurements at two locations in the same plate were strongly correlated with measured geometrical heterogeneity in the plate—a tilt in the fuel foil. Compressive stresses in the U-10Mo were shown to increase from 20 to 250 MPa as the ratio of aluminum thickness to U-10Mo thickness increased causing increased constraint during cooling. Faster cooling rates during processing also increased stress magnitudes. Conclusions The measurements trends agreed with data in the literature from similar plates made with DU, which further validates the method. Because other methods are impractical in a hot cell, the modified slitting method is now poised for the first measurements of post-irradiation stresses.

The Waste Package Closure System, for the closure of radioactive waste in canisters for permanent storage of spent nuclear fuel (SNF) and high-level waste in the Yucca Mountain Repository, was designed, fabricated, and successfully demonstrated at the Idaho National Laboratory. This paper focuses on the robotic hardware and tools necessary to remotely weld and inspect the closure lid welds. The system was operated remotely and designed for use in a radiation field due to the SNF contained in the waste packages being closed.

This paper presents a robotic system for GTA welding of lids on cylindrical vessels. The system consists of an articulated robot arm, a rotating positioner, end effectors for welding, grinding, ultrasonic and eddy current inspection. Features include weld viewing cameras, modular software, and text-based procedural files for process and motion trajectories.

This paper presents a robotic system for GTA welding of lids on cylindrical vessels. The system consists of an articulated robot arm, a rotating positioner, end effectors for welding, grinding, ultrasonic and eddy current inspection. Features include weld viewing cameras, modular software, and textbased procedural files for process and motion trajectories.

This presentation describes the design, fabrication and testing of a friction stir processing machine. The machine is intended to be a flexible research tool for a broad range of friction stir processing studies. The machine design also addresses the need for an affordable, robust design for general laboratory use.

Canisters for long term storage or disposal of waste materials are normally closed by welding one or more lids to the top of the canister. This paper describes the development of a conceptual design of a control architecture for a robotic system for welding lids on canisters in a remote welding cell. This work extended over several years and included development of control systems for three machines.

The cupola furnace is used to melt scrap steel, pig iron, foundry returns and alloying additives to a prescribed tapping chemistry and temperature for iron casting applications. The melting process within the cupola is highly complex and not well quantified. The American Foundrymen's Society is developing a mathematical model to aid in the understanding of these processes. This model is reaching maturity, and has been successful in estimating a number of melting parameters. This paper details the results of efforts to verify the model in a controlled system, equipped with the appropriate sensors, for model verification. The work was performed on a research-scale cupola furnace located at the Department of Energy's Albany Research Center.

In this paper we present some final results from a research project focused on introducing automatic control to the operation of cupola iron furnaces. The main aim of this research is to improve the operational efficiency and performance of the cupola furnace, an important foundry process used to melt iron. Previous papers have described the development of appropriate control system architectures for the cupola. These results are summarized. Then we describe the experimental results obtained with the U.S. Department of Energy Albany Research Center`s research cupola. First, experimental data is used to calibrate the model, which is taken as a first-order multivariable system with time delay. Then relative gain analysis is used to select loop pairings to be used in a multi-loop controller. The resulting controller pairs meltrate with blast volume, iron temperature with oxygen addition, and carbon composition with percent coke. Special (nonlinear) filters are used to compute meltrate from actual scale readings of the amount of iron produced and to smooth the temperature measurement. The temperature and meltrate loops use single-loop PI control. The composition loop uses a Smith predictor to discount the deadtime associated with mass transport through the furnace. Experimental results validate the conceptual controller design and provide proof-of-concept of the idea of controlling a foundry cupola. Future research directions are discussed, including the concept of an integrated, intelligent industrial process controller, or I{sup 3}PC.

Control of gas metal arc welding (GMAW) requires real-time sensing of the process. Three sensing techniques for GMAW are being developed at the Idaho National Engineering Laboratory (INEL). These are (1) noncontacting ultrasonic sensing using a laser/EMAT (electromagnetic acoustic transducer) to detect defects in the solidified weld on a pass-by-pass basis, (2) integrated optical sensing using a CCD camera and a laser stripe to obtain cooling rate and weld bead geometry information, and (3) monitoring fluctuations in digitized welding voltage data to detect the mode of metal droplet transfer and assure that the desired mass input is achieved.