1

Development of Robust Technology and Designs for Handling LEU-Foil Development of Robust Technology and Designs for Handling LEU-Foil Annular Targets for Production of Mo-99 that shall Fulfil the following Annular Targets for Production of Mo-99 that shall Fulfil the following Requirements and Constraints:Requirements and Constraints:

Project ObjectivesProject Objectives

1- Flexibility, in order to accommodate different target geometries, materials, and production volumes with minimum efforts and cost.

2- Affordability, for USA domestic production as well as for other countries.

3- Safety and Quality Assurance, for meeting rules and regulation.

4- Productivity, for meeting USA domestic needs for fission product Mo-99.

5- Training US Young Engineers and Scientists for developing effective nuclear technology for energy and biomedical applications of the future.

Large Scale Production of Mo-99

Production Process Design GroupSherif El-Gizawy, Brian Graybill, James Berlin,

Emily Ferner, Annemarie Hoyer

Design Analysis is Required as Part of “Safety Case” Documentation to Demonstrate Target’s Structural Integrity

during Target Assembly

The Followings are the Required Design Tasks

Develop model and perform Detailed Finite Element Analysis of an assembled LEU-foil target.

The model will include the target’s drawing process of all foils and the Aluminum tubes.

Experimental testing and Measurements to verify the developed models, (residual stresses, microstructure, surface roughness, waviness, and contact profile).

This design analysis is parametric and applicable to any target design and can be used to determine inner tube minimum wall thickness that will withstand the maximum predicted operating pressure in order to assure “zero” target structural failures during irradiation

Mechanical and Aerospace EngineeringUNIVERSITY OF MISSOURI-COLUMBIA Dr. Sherif El-Gizawy, July 11, 2011 3

Df

Outer TubeOuter Tube

Drawing ForceDrawing Force

α

DoInnerInnerTubeTube

PunchPunch

DeformationDeformationZoneZone

Assembly Process Analysis Assembly Process Analysis

•Process design to allow for deformation zone that covers the entire inner tube thickness.Process design to allow for deformation zone that covers the entire inner tube thickness.

•Force is applied through the punch. Deformation of the wall of the inner tube isForce is applied through the punch. Deformation of the wall of the inner tube is caused by Compressive stresses along axial, radial and hoop directions.caused by Compressive stresses along axial, radial and hoop directions.

Mechanical and Aerospace EngineeringUNIVERSITY OF MISSOURI-COLUMBIA Dr. Sherif El-Gizawy, July 11, 2011 4

σh

σr

σz

Fz

Draw Stress,dr = fmQdr = fm .Qfr . Where Qfr = (1+cot)

= ln(Ao/A1)

L

h12.088.0

Drawing Force, Fdr = dr* A

*, FPPower /, PTorque

Finite Element AnalysisFinite Element Analysis

Modeling of the target assembly is completed using the FEM ANSYS structural package. These analyses serve three major purposes:

1) Determine the force necessary to plastically deform the inner tube against the outer tube, resulting in a bond that will be maintained throughout irradiation.

2) Determine the residual stresses in the assembled target after assembly. It is critical that the tensile stress in the outer tube is maintained so that it will “spring open” when cut, resulting in easy removal of the inner tube and irradiated target.

3) The development of a parametric model provides a platform for faster analysis for the investigation of target shapes/dimensions that vary from the Indonesian target

Outer Tube

Inner Tube

Drawing Die

Plug

Drawing Die SetDrawing Die Set

Outer Tube

Uranium Foil

Nickel Foil

Inner Tube

LEU Foil inside the Nickel EnvelopLEU Foil inside the Nickel Envelop

Finite Element ModelsFinite Element Models•The Workbench layout of ANSYS allows for easy alteration of the original model, allowing for several geometries to be investigated without significant input from the user.•Once a dimension has been changed upstream, the rest of the model simply needs to be refreshed and/or updated to achieve the new results.

7

FEM Simulation Results for Target Drawing Using Floating Conical Plug

Design

Typical Floating Conical Plug Design

Cylinder Punch

Linear Guide Bearing

Push Rod

Hydraulic Ram

Hydraulic Pump

Quality Control Gauge

System Overview

RAM Force

Swaging Process Cut Away

RAM Force

Swaging Process Cut Away

Removal

Parametric Analysis of Annular Target/ Assembly Process DesignParametric Analysis of Annular Target/ Assembly Process DesignUsing Design of Industrial ExperimentsUsing Design of Industrial Experiments

Partial Factorial• Basic matrix setup• Partial factorial setup

allows for fewer initial experiments

• The initial setup will serve to direct a more focused, comprehensive experimental array

• Quality Characteristics Quality Characteristics (Responses , Y): (Responses , Y): 1- 1- Integrity of the Target Integrity of the Target (visual) , 2-Thermal (visual) , 2-Thermal Contact Resistance, 3- Contact Resistance, 3- Forming Pressure, 4- Gap Forming Pressure, 4- Gap Size at the Contact with Size at the Contact with Target Walls (SEM Target Walls (SEM measurements of measurements of sectioned targets).sectioned targets).

Factors

Experiment Punch Diam.Punch Angle

alpha relief thickness (t) per side Target Material1 1 1 1 12 1 2 2 23 1 3 3 34 2 1 2 35 2 2 3 16 2 3 1 27 3 1 3 28 3 2 1 39 3 3 2 3

Mechanical and Aerospace EngineeringUNIVERSITY OF MISSOURI-COLUMBIA Dr. Sherif El-Gizawy, July, 11, 2011 14

Foil Materials Aliened Foil Materials Aliened insideinside

The Relief areaThe Relief area

Inner Inner Aluminum Aluminum

TubeTube

Outer Outer AluminuAluminum Tubem Tube

AABB

A- Significant Voids Exist A- Significant Voids Exist B- Zero Gap CaseB- Zero Gap Case (Unsuccessful) Case(Unsuccessful) Case

Intimate Contact Evaluated by SEM for Gap ObservationIntimate Contact Evaluated by SEM for Gap Observation

Work for the next 3 months

• Complete the partial factorial• Determine which variables are most sensitive to

change• Use results to develop and execute a

comprehensive response-surface type experimental array, explore and characterize variable interactions (Phase II)

• These results will produce a single predictive equation to determine desired outputs from the input variables shown here

21122

2222

11122110 xxxxxxY

Design of Experiment (Phase II)Design of Experiment (Phase II)Response Surface Method (RSM)Response Surface Method (RSM)

Two Parameter central composite design. Two Parameter central composite design.

Parameters:Parameters: Relief Size(xRelief Size(x11), Punch Diameter(x), Punch Diameter(x22).).

Responses (Y):Responses (Y): 1-Thermal Contact Resistance, 2-Fraction 1-Thermal Contact Resistance, 2-Fraction Volume of Voids or Gab at the Contact with Target Walls, Volume of Voids or Gab at the Contact with Target Walls,

3- Forming Pressure.3- Forming Pressure.

Second Order Response surface modelsSecond Order Response surface models

Fitted 3-D surface and equation of the Torque, (lb.ft), in Titanium

0.267 0.284 0.301 0.319 0.336 0.353 0.371 0.388 0.405 0.423 above

Fitted Surface; Variable: TORQUE

TORQUE in Titanium (lb.ft)

z=-3.086263241604+.010844907560897*x-.0000078517515508477*x^2+605.22238525195*y+98596.285487694*y^2-1.46482990521*x*y+0.

Example of Typical Results

Process contour maps of torque, (lb.ft), during drilling TitaniumProcess contour maps of torque, (lb.ft), during drilling Titanium

0.267 0.284 0.301 0.319 0.336 0.353 0.371 0.388 0.405 0.423 above

Fitted Surface; Variable: TORQUE

TORQUE in Titanium (lb.ft)

SPEED (rpm)

FE

ED

(ip

r)

0.0008

0.0009

0.0010

0.0011

0.0012

0.0013

0.0014

0.0015

0.0016

460 480 500 520 540 560 580 600 620 640

Mechanical and Aerospace EngineeringUNIVERSITY OF MISSOURI-COLUMBIA Dr. Sherif El-Gizawy, July, 11, 2011 19

Future Work by the Production Process Design Group

20

TIG EB Forming

Sealing Ends of the Annular TargetsSealing Ends of the Annular Targets

Target Disassembly DeviceTarget Disassembly Device

SEVEN Degrees of FreedomSEVEN Degrees of FreedomRobotic Arm for Handling Robotic Arm for Handling

Targets inside Hot CellTargets inside Hot Cell