A study on cubic boron nitride (CBN) milling of hardened cast iron for productive and quality manufacturing of machine tool structural components

To improve efficiency and cost performance of cast iron machine tool component fabrication, an alternative process must be developed in order to replace the grinding process, which often causes a bottleneck in production. As an alternative manufacturing approach, this research applies cubic boron nitride (CBN) hard milling operations to eliminate the grinding process in order to improve the overall manufacturing process. A variety of hardened cast iron materials with Al and Mg additives and CBN tool types were prepared and tested based on a design of experimentation (DOE) to observe their effect on surface quality and tool life. Al and Mg were added to raw cast iron to achieve generation of oxide layers at the cutting edge during milling to protect the tool from wear. By executing the DOE, the optimal cutting conditions for achieving the best surface quality were introduced. Also, additional machinability tests were conducted with the optimal conditions in order to evaluate tool wear characteristics and surface quality of the machined workpieces. Based on the observation of the used tool by electron probe micro-analyzer (EPMA), a protective oxide layer of additives was observed at the cutting edge. Hardened cast iron with Al and Mg additives is found to show preferable wear and surface quality characteristics.     

Design research of small long life CANDLE fast reactor

The feasibility of a small long life fast reactor with CANDLE burn-up concept was investigated. It was found that a core with 1.0 m radius and 2.0 m length can bring about CANDLE burn-up with nitride (enriched N-15) natural uranium as fresh fuel. Lead–Bismuth is used as coolant. From equilibrium analysis, we obtained the burn-up velocity, output power distribution, core temperature distribution, etc. The burn-up velocity is less than 1.0 cm/year, which easily permits a long core life design. The averaged core discharged fuel burn-up is about 40%. For better understanding of the effect of the coolant to fuel volume ratio, comparison was made among five cases. In these cases the coolant channel radii were different from one case to another, while fuel pin pitch was fixed. Comparisons were also made with a fixed coolant channel radius and different fuel pin pitches. A simulation of core operation is implemented and the results show that the present design can establish the long time steady CANDLE burn-up successfully without a burn-up control mechanism.     

Maximization of representativity factors for experimental planning of cross-section measurements: An information theoretic approach

The similarity between two nuclear systems is expressed by the representativity factors and maximizing its value to unity reduces the uncertainty from its existing value. As the representativity factor is a function of covariance matrix of neutron cross-sections, the inherent systematic uncertainty in neutron cross-sections inhibits it from approaching unity and hence statistical procedures have to be resorted to minimize the systematic uncertainty. As the conventional statistical techniques fail when systematic uncertainty is dominant, we propose an entropy based information theoretic approach of maximizing the mutual information by the knowledge of bounds for the correlated elements. We show that maximizing the mutual information and the representativity factors express the similar phenomena of uncertainty reduction. We estimated the bounds for the correlated elements of the correlation matrix for minor actinides and show how the systematic uncertainty is reduced when lower bound values are considered. These lower bound values aid in experimental planning for future measurement of cross-sections with reduced systematic uncertainty.     

Main R&D issues for fast reactor structural design standard

For realization of economical and reliable fast reactor (FR) plants, the Japan Atomic Energy Agency (JAEA) and the Japan Atomic Power Company (JAPC) are cooperating on the “Feasibility Study on Commercialized FR Cycle Systems”. To certify the design concepts through evaluation of the structural integrity of FR plants, the research and development of the “Elevated Temperature Structural Design Guide for Commercialized Fast Reactor (FDS)” is recognized as an essential theme. The FDS focuses on particular failure modes of FRs such as ratchet deformation and creep-fatigue damage due to cyclic thermal loads. For precise evaluation of these modes, the research and development for three main issues is in progress. First, the “Refinement of Failure Criteria” needs to be addressed for particular failure modes of FRs. Secondly, the development of “Guidelines for Inelastic Design Analysis” is conducted to predict elastic plastic and creep deformation under elevated temperature conditions. Lastly, efforts are being made toward preparing “Guidelines for Thermal Load Modeling” for the design of FR components where thermal loads are dominant.     

Clarification of strain limits considering the ratcheting fatigue strength of 316FR steel

The effect of ratcheting on fatigue strength was investigated in order to rationalize the strain limit as a design criterion of commercialized fast reactor systems. Ratcheting fatigue tests were conducted at 550 °C. Duration of the ratchet straining was set for a certain number of strain cycles taking the loading condition of fast reactors into account, and the number of cycles for strain accumulation was defined as the ratchet-expired cycle. Fatigue lives decrease as the accumulated strain by ratcheting increases. Mean stress increased during the ratcheting cycle and its maximum value depended on the accumulated strain and the ratchet-expired cycle. Fatigue life reduction was negligible when the maximum mean stress was less than 25 MPa, corresponding to an accumulated strain of 2.2%. Accumulated strain is limited to 2% in the present design guidelines and this strain limit is considered effective to avoid reducing fatigue life by ratcheting. Microcrack growth behaviors were also investigated in these tests in order to discuss the life reduction mechanisms in ratcheting conditions.     

Performance of natural uranium- and thorium-fueled fast breeder reactors (FBRs) for U fissile production

The performance of natural uranium and thorium-fueled fast breeder reactors (FBRs) for producing ²³³U fissile material, which does not exist in nature, is investigated. It is recognized that excess neutrons from FBRs with good neutron economic characteristics can be efficiently used for producing ²³³U. Two distinct metallic fuel pins, one with natural uranium and another with natural thorium, are loaded into a large sodium-cooled FBR. ²³³U and the associated-U isotopes are extracted from the thorium fuel pins. The FBR itself is self-sustained by plutonium produced in the uranium fuel pins. Under the equilibrium state, both uranium and thorium spent fuels are periodically discharged with a certain discharge rate and then separated. All discharged fission products are removed and all discharged actinides are returned to the FBRs except the discharged uranium utilized for fresh fuel of the other thorium-cycled reactors. ²³³U-production rate of the FBRs as a function of both the uranium–thorium fuel pins fraction in the core and the discharge fuel burnup is estimated. The result shows that larger fraction of uranium pins is better for the FBR criticality while larger fraction of thorium fuel pins and lower fuel burnup give higher ²³³U production rate.     

Synthesis and applications of magnetic nanoparticles for biorecognition and point of care medical diagnostics

Functionalized magnetic nanoparticles are important components in biorecognition and medical diagnostics. Here, we present a review of our contribution to this interdisciplinary research field. We start by describing a simple one-step process for the synthesis of highly uniform ferrite nanoparticles (d = 20-200 nm) and their functionalization with amino acids via carboxyl groups. For real-world applications, we used admicellar polymerization to produce 200 nm diameter 'FG beads', consisting of several 40 nm diameter ferrite nanoparticles encapsulated in a co-polymer of styrene and glycidyl methacrylate for high throughput molecular screening. The highly dispersive FG beads were functionalized with an ethylene glycol diglycidyl ether spacer and used for affinity purification of methotrexate-an anti-cancer agent. We synthesized sub-100 nm diameter magnetic nanocapsules by exploiting the self-assembly of viral capsid protein pentamers, where single 8, 20, and 27 nm nanoparticles were encapsulated with VP1 pentamers for applications including MRI contrast agents. The FG beads are now commercially available for use in fully automated bio-screening systems. We also incorporated europium complexes inside a polymer matrix to produce 140 nm diameter fluorescent-ferrite beads (FF beads), which emit at 618 nm. These FF beads were used for immunofluorescent staining for diagnosis of cancer metastases to lymph nodes during cancer resection surgery by labeling tumor cell epidermal growth factor receptor (EGFRs), and for the detection of brain natriuretic peptide (BNP)-a hormone secreted in excess amounts by the heart when stressed-to a level of 2.0 pg ml(-1). We also describe our work on Hall biosensors made using InSb and GaAs/InGaAs/AlGaAs 2DEG heterostructures integrated with gold current strips to reduce measurement times. Our approach for the detection of sub-200 nm magnetic bead is also described: we exploit the magnetically induced capture of micrometer sized 'probe beads' by nanometer sized 'target beads', enabling the detection of small concentrations of beads as small as 8 nm in 'pumpless' microcapillary systems. Finally, we describe a 'label-less homogeneous' procedure referred to as 'magneto-optical transmission (MT) sensing', where the optical transmission of a solution containing rotating linear chains of magnetic nanobeads was used to detect biomolecules with pM-level sensitivity with a dynamic range of more than four orders of magnitude. Our research on the synthesis and applications of nanoparticles is particularly suitable for point of care diagnostics.     

Fade and quench-resistant emission in calcium phosphate nanoreactors

The fluorescence emission and photodegradation properties of fluorescein dye inside fluid-filled spherical nanoreactors ～ 150 nm in diameter and surrounded by a few nanometres thick layer of calcium phosphate are considered in detail. Steady state, stopped flow, and laser pulsed fluorescence spectroscopies, absorption spectroscopy, dynamic light scattering and electron microscopy were used to characterize the materials as a function of encapsulated dye concentration, particle concentration, illumination time, and pH. Fluorescein tends to form stable J-aggregates inside the nanoreactors. The molecular collision rate constants between the dye aggregates and between the dyes and soluble quenchers are greatly reduced inside the nanoreactors and are responsible for the observed resistance to photodegradation and reduced emission quenching. A model for dye behaviour in nanoreactors is suggested. Nanoreactors can be concentrated to a high suspension concentration, yielding exceptionally strong luminescence affected only by inner filter effects absent particle-particle crosstalk. These and similar nanoreactors can be utilized as building blocks for three-dimensional photo-optical devices, and as versatile and resilient supramolecular chromophores or tracers in complex fluids, cells and microfluidic systems where high resolution visualization is needed.     

Developments of new concept analytical instruments for failure analyses of sub-100 nm devices

We have developed analytical instruments based on new concepts for failure analyses of devices of 100 nm dimensions or less. They are a sputtered neutral mass spectrometer with focused ion beam for highly sensitive element analysis in microarea (10¹⁸ atoms/cm³ in 30 nm area), transmission electron microscope (TEM) with electron energy loss spectrometer for chemical bond analysis in less than 2 nm area, Nanoprober for electrical characteristics inspection in actual circuits, computed tomography-TEM for three-dimensional observation of crystalline defect with 1 nm spatial resolution, atmospheric pressure ionization mass spectrometer for trace impurities ppq (parts per quadrillion) analysis in gases, and glow discharge optical emission spectrometer for rapid and precise composition analysis. Using these instruments, it was found that the formation of SiO₂ or TiO_x film by water from titanic acid (TiO_x·H₂O) is the cause of the high resistivity in a contact (CVD-W/CVD-TiN/Ti/Si) and vaporization of silicon dioxide by phosphorus trifluoride (PF₃) is the cause of voids in interlayer dielectric film borophosphosilicate glass.     

Composite Copper Clad Laminates CEM—3 ELC—4970 Series

Outline of the Product Composite Copper Clad Laminates are made from more than two kinds of materials using CEM-1 and CEM-3 as its main grades.