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A Comprehensive Modeling Tool for Cold Hearth Melting Processes

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-06-C-5206
Agency Tracking Number: F051-130-3444
Amount: $749,971.00
Phase: Phase II
Program: SBIR
Solicitation Topic Code: AF05-130
Solicitation Number: 2005.1
Timeline
Solicitation Year: 2005
Award Year: 2006
Award Start Date (Proposal Award Date): 2006-04-24
Award End Date (Contract End Date): 2008-08-24
Small Business Information
215 Wynn Dr., 5th Floor
Huntsville, AL 35805
United States
DUNS: 185169620
HUBZone Owned: No
Woman Owned: Yes
Socially and Economically Disadvantaged: No
Principal Investigator
 HQ Yang
 Chief Scientist
 (256) 726-4800
 jls@cfdrc.com
Business Contact
 Ashok Singhal
Title: President
Phone: (256) 726-4800
Email: aks@cfdrc.com
Research Institution
N/A
Abstract

Under AFRL Contract FA8650-05-M-5214 Phase I, CFDRC has developed and demonstrated the foundation of a comprehensive code for modeling the Cold Hearth Melting (CHM) processing of Titanium alloys. The code includes effects that accurately predict the transient temperature distribution, flow patterns, skull shape, species evaporation, and particle fates in the hearth region for a given set of dynamic operating conditions. Parity with the current state of the art in modeling the CHM process has successfully been demonstrated in Phase I. In Phase II, we will improve the scope, speed and accuracy of the code using an innovative combination of advanced numerical tools and expertise unique to CFDRC. These advanced tools include parallel processing, binary tree and adaptive grids, advanced turbulence models, particle tracking, free surface modeling with Marangoni effects, Monte Carlo for radiative heat transport, and rarified gas dynamics with evaporation and deposition. These capabilities will be coupled and integrated into a user-friendly software package. The development will be performed in close collaboration with the industry to ensure relevance and facilitate technology transfer. The code can offer direct benefit to the industrial processes by: 1. Improving hearth designs and control systems; 2. Optimizing operating conditions; 3. Sensitivity to operating conditions and studying various “what if” scenarios without expensive experimentation. In Phase III, the engineering knowledge and simulation capability developed in Phase II will be used as enabling technology for the improvements in hearth melting technology and ensuring defect-free materials.

* Information listed above is at the time of submission. *

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