Filler materials

Insurance in pressure boundary integrity of NPP unit is strongly influenced by technical capabilities and efficiency of metal examination system. Ordinary ultrasonic examination tools and procedures have limitations in flaw sizing and positioning. The problems arise for welds and repair zones of welds made by filler materials of austenitic type. 

Phenol—formaldehyde (PF) was the first of the synthetic adhesives developed. By combining phenol with formaldehyde, which has exceptional cross-linking abiHties with many chemicals and materials, and a small amount of sodium hydroxide, a resin was obtained. The first resins soHdified as they cooled, and it was discovered that if it was ground to a powder with a small amount of additional formaldehyde and the appHcation of more heat, the mixture would Hquify and then convert to a permanently hard material. Upon combination of the powdered resin mixture with a filler material such as wood flour, the result then being placed in a mold and pressed under heat and pressure, a hard, durable, black plastic material was found to result. For many years these resulting products were called BakeHte, the trade name of the inventor. BakeHte products are still produced today, but this use accounts for only a small portion of the PF resins used. 

Reverberator Furnace. Using a reverberatory furnace, a fine particle feed can be used, the antimony content can be controlled, and batch operations can be carried out when the supply of scrap material is limited. However, the antimony-rich slags formed must be reduced in a blast furnace to recover the contained antimony and lead. For treating battery scrap, the reverberatory furnace serves as a large melting faciUty where the metallic components are hquefted and the oxides and sulfate in the filler material are concurrently reduced to lead metal and the antimony is oxidized. The furnace products are antimony-rich (5 to 9%) slag and low antimony (less than 1%) lead. 

Fillers. Materials used as fillers (qv) in mbber can also be classified as acidic, basic, or neutral. Furnace blacks, ie, HAF, FEF, or SRF, are somewhat basic. As such, they can have an activating effect on sulfur cure rates. Furthermore, carbon blacks have been found to promote formation of mono/disulfide cross-links thereby helping minimize reversion and enhance aging properties. 

For shipping purposes, the ampul is placed in aluminum foil or polyethylene bags. The wrapped ampul is packed in a metal can and surrounded by an inert filler material such as vermiculite. These precautions are necessary in order to minimize the chances of ampul breakage during shipment. Most mbidium compounds, however, can be shipped as nonhazardous materials. These compounds are usually stored in glass or polyethylene botdes. 

Low sulfur and ash levels are required for high GTE, isotropic cokes used for carbon and graphite specialty products. Highly isotropic cokes are also the filler materials for producing graphite for nuclear reactors. The purity, particularly the boron content, is critical in this appHcation. Properties of typical needle and isotropic (regular) cokes are summarized in Table 1. 

Glassy, or vitreous, carbon is a black, shiny, dense, brittle material with a vitreous or glasslike appearance (10,11). It is produced by the controUed pyrolysis of thermosetting resins phenol—formaldehyde and polyurethanes are among the most common precursors. Unlike conventional artificial graphites, glassy carbon has no filler material. The Hquid resin itself becomes the binder. 

Directed Oxidation of a Molten Metal. Directed oxidation of a molten metal or the Lanxide process (45,68,91) involves the reaction of a molten metal with a gaseous oxidant, eg, A1 with O2 in air, to form a porous three-dimensional oxide that grows outward from the metal/ceramic surface. The process proceeds via capillary action as the molten metal wicks into open pore channels in the oxide scale growth. Reinforced ceramic matrix composites can be formed by positioning inert filler materials, eg, fibers, whiskers, and/or particulates, in the path of the oxide scale growth. The resultant composite is comprised of both interconnected metal and ceramic. Typically 5—30 vol % metal remains after processing. The composite product maintains many of the desirable properties of a ceramic however, the presence of the metal serves to increase the fracture toughness of the composite. 

Any tests and associated acceptance criteria which are part of the welding-procedure qualification for filler materials and heat-affected zone need not he repeated. 

An example of a practical dielec trofilter which uses both of the features described, namely, sharp electrodes and dielectric field-warping filler materials, is that described in Fig. 22-34 [H. I. Hall and R. F. Brown, Lubric. Eng., 22, 488 (1966)]) It is intended for use with hydrauhc fluids, fuel oils, lubricating oils, transformer oils, lubricants, and various refineiy streams. Performance data are cited in Fig. 22-35. It must be remarked that in the opinion of Hall and Brown the action of the dielec trofilter was electrostatic and due to free charge on the particles dispersed in the hquids. It is the present authors opinion, however, that both elec trophoresis and dielectrophoresis are operative here but that the dominant mechanism is that of DEP, in wdiich neutral particles are polarized and attracted to the regions of highest field intensity. 

Access for foe filler material and/or processiog heat during welding is an important considentioD, Awkward positions should be avoided and ideally processing should be pofonned fiom above. 

Filler Material Chemical Resistance Heat Resistance Electrical Insulation Impact Strength Tensile Strength ... 

Visible exudation or efflorescence on the surface of a plastic caused by plasticizer, lubricant, etc. Spacer or filler material in a mold. 

Various filler materials and their property contributions to... 

Coupling Agents. Coupling agents are added to improve the bonding of the plastic to inorganic filler materials, such as glass fibres. A variety of silanes and titanates are used for this purpose. 

Bimetallic corrosion of nickel-iron alloys may be of significance in welding operations. Ni-45 Fe alloys are used as filler materials in the welding of cast irons but the favourable area relationship of weld metal to base plate... 

The welded joint differs from all others in that an attempt is made to produce a continuity of homogeneous material which may or may not involve the incorporation of a filler material. There are a large variety of processes by which this may be achieved, most of which depend upon the application of thermal energy to bring about a plastic or molten state of the metal surfaces to be joined. The more common processes used are classified in Table 9.6. 

The active coating consists of a thermally deposited mixed metal oxide coating, the composition of which is considered proprietary information, although it is known that certain filler materials, e.g. Ta, may be added to the mixed metal oxide to reduce the precious metal content of the coating, and hence the cost of the anode. 

In dispersed systems the nature of the filler also plays a controlling role in the way the crystallization proceeds. Examples are reported in [105], whose authors have used X-ray analysis to estimate the degree of crystallinity of polyisobutylene filled with different concentrations of a number of filler materials, after 100 cycles of 50% stretching. Polyisobutylene crystallizes as a result of such treatment. The results are given in Table 1. 

A different type of low friction or low drag application is encountered with sliding doors or conveyor belts sliding on support surfaces. In applications like this the normal forces are generally quite small and the friction load problems are of the sticking variety. Some plastics exhibit excellent track surfaces for this type of application. TFEs have the lowest coefficient of any solid material and represent one of the most slippery surfaces known. The major problem with TFE is that its abrasion resistance is low so that most of the applications utilize filled compositions with ceramic filler materials to improve the abrasion resistance. 

The polishing pad, as another consumable material, also has a dominating effect in the CMP process, which is usually made of a matrix of cast polyurethane foam with filler material to control hardness of polyurethane impregnated felts. The pad carries the slurry on top of it, executes the polishing action, and transmits the normal and shear forces for polishing, thereby playing a very cnacial role in process optimization [44 6]. 

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